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Forging dies manufacturing is the first step to start a forging part.We all know that forging can be generally classified into two types,open die forging and closed die forging.Open die forging is operated between flat dies or dies in a simple shape.This process is mainly used for large parts.In closed die forging,metal billet is deformed in upper and lower dies for desired shape and dimensions.Deformation occurs in the closed cavity under high pressures,which will achieve precision forgings with tight tolerances.So this process is widely used for the manufacture of simple as well as complex high strength precision parts,especially when safety factor is considered.As a closed die drop forging manufacturer,we would like to introduce the forging dies manufacturing for closed die forging parts in detail.

Before manufacturing of forging dies,we can not start the production process directly.Firstly,engineer need to know how to design the forging dies following the drawing of a new forging part.Design of forgings dies depends on the processing steps,nature of workpiece material,flow stress,working temperature,ect.All these factors need to be considered.Generally speaking,we need to calculate the volume of billet accurately to aviod under filling or excess filling.And selection of parting line(referring the lind where two dies meet) is also important.Sometimes for a forging part,there are several options to choose a parting line.And the best one is that the parting line can ensure the flow of material will be uniformly divided.In other words,forging is not feasible if there is no way to decide parting line,in this case,casting can be considered.
differences between forging and casting
Forging is processing way that putting pressure on metal blank by forging machinery, making it produce plastic deformation, in order to obtain certain mechanical properties, a certain shape and size of forgings. Forging can eliminate the as-cast osteoporosis of the metal, welded holes, and generally mechanical properties of forging is better than that of the same material of the casting.So for those important components that require to undertake high mechanical load, or working in serious conditions, in addition to simple shape rolling plate, or welding parts are available, all will consider forging process.

Casting is a metal forming process that melting the metal into certain requirements of the liquid and then pouring it into the mold,after cooling solidification,we can get desired shape and sizes.Production cost of blanks produced by casting is low.For complex shape, especially the parts with complex inner cavity, casting can show its economical efficiency more; At the same time, it has a wide adaptability,and has better comprehensive mechanical properties. But materials that needed in casting production and equipments (such as metallurgical furnace,sand mixing machine,molding machine, core making machine, shakeout machine, shot blasting machine, etc.) will produce dust, harmful gas and noise.Thus it will do harm to environmental.
Casting is the oldest metal processing process that first melting metals into liquid  status,then pouring metal liquid in injection moulds,and cooling a while to obtain the required shape or dimensions.When products are not suitable for forging,casting is the economic method for blank shape.Especially for complex shape parts,casting can show its efficiency more.

Size and weight range of casting parts is very wide,almost unlimited metal species;Parts that have general mechanical properties,but also has comprehensive performance like wear-resisting,corrosion resistance,shock absorption,which is better than other metal forming methods,such as forging,rolling,welding,punching,etc.So metal blanks produced by the method of casting process are still the most on the quantity and tonnage so far.
Forging is a metal processing process that using forging pressure machines to put pressure on metal blank,which will produce plastic deformation in order to obtain certain mechanical properties,a certain shape and dimensions.Forging can eliminate the as-cast loose defects that produced on metal smelting process,optimizing the microstructure,and meanwhile can preserve intact metal flow.So mechanical properties of forgings generally are better than that of the same material castings.

As one of the main metal processing process,applications of forgings are so wide.Such forgings are mostly used by people when safety factor is considered and good mechanical properties are needed.So forgings can be used in mining machinery(mining drill bits),agricultural machinery(agricultural wear parts),forestry machinery(mulcher hammer/teeth),automotive industry,trailer parts,ect.Click our photo gallery page can help you to learn more about forging applications.
flail moverFlail mover is the cutting device used in garden,agricultural or forestry application,which is designed when lots of cutting power and a rougher cut is needed.Most applicated flial mover work on places with taller vegetation like meadows, road banks, yard areas,and so on.

Flail mowers may also be used in a more or less upright position for trimming the sides of hedges. They are often called hedge cutters (or sometimes also hedge trimmers) then. Especially in forestry (agroforestry) some very robust variants of flail mowers – called flail mulchers, flail shredders, or flail choppers – are used.
Flail hammer blades or Knives blades for flail movers"I would like to buy an Orsi 209 flail mover delivered with Y knives blades,but I preferred flail hammer blades. I'm just puzzlled which one is more suitable. I want to promote good pasture health in the paddocka,but also a nice finish on my lawn areas around the house.The flail mover will also be used for clearing of regrowth where there is a strong possibility of hitting tree stumps and branches, and small and large rocks. It will be much appreciated if any experience or opinions are provided."

When you design o buy a new flail mower, you will have a choice of the Y Knife Blades or Hammer Blades. The Y-Blades are great when cutting tall weeds and overgrowth and can also offer a nice cut to your lawn. However,if you are need to cut tree saplings and dense overgrowth,the flail hammer blades are used,which are wider, heavier blades than the Y-blades. No matter Flail hammer blades or Y knife blades,either set of blades will make a perfect solution for cutting.
In forging industry,there are some professional terms which are defined to describe the forging process or operations.Below we picked out some common terms when used in closed die forging process.

1)Forging die:It may be referred to a complete tool consists of a pair of mating members for producing work by hammer or press.A pair of forging dies consists of upper and lower die halves with cavities. 
2)Billet:A slug cut from rod ready to be heated and forged. 
3)Blocker:Preform die or impression,used when part cannot be made in a single operation. 
When purchasers need a metal forming process for their precision design or products,they may have lots of considerations,such as quality,economy,ect.With the development of modern industry,there are all kinds of metalworking processes for choosing,such as casting,forging,powder metallurgy,stamping,machining,ect.Each metalworking process offers a unique set of costs,advantages and capabilities.When safty and strength factors are required,closed die forging process will be your best choice.In fact,closed die forging is often the optimum process,in terms of both part quality and cost-efficiency-especially for applications that require maximum part strength,special sizes or critical performance specifications.

In fact,in terms of forging,there are also several kinds of forging processes available,such as open die forging,closed die forging,cold forging,and extrusion.However,here we will discuss the methods,application and bennefits of closed die forging process.We suggest you to consider this process when selecting the optimum process for your metal parts production.
Closed die forging is commonly used in nowadays for many improtant metal components.On one hand,is that it can product metal products with good properties.On the other hand,the price of closed die forging is also competitive than casting.In other words,closed die forging also has economic advantages.

Material

Before forging,we will first need to cut the equal billet according to the size of products.Normally,the waste of material after forging is the flash.So comparing with casting or machining,closed die forging requires less material,thus material cost will be saved.Take a round ring for example,we can make it by forging or machining.If machining,the all corner and the center material will be wasted.But with forging,we can forged to the sizes with minimum waste.
Linear dimension
Linear dimension,or size,it is to point to the distance between two points,such as diameter,radius,depth,width and height,center distance,etc.To express the dimensions of drop forgings exactly,lots of linear dimensions will be show in a drawing.After finish production of products,we will test all these linear dimensions by vernier caliper or digital caliper,to check if these dimensions are within the required tolerances.For outer diameter,it will be more accurate to use outside micrometers.

Angular dimensions 
Angular dimensions are usually shown the size of Angle,like 30,such angular is tested by universal bevel protractor.
To remove the stress and improve mechanical properties of drop forging,heat treatment will be done after forging.Such heat treatment can be normalization,tempering,quenching,temperting&hardening,ect.To test the heat treatment result,we may test the tensile strength,yield stength,enlongation,hardness,among these mechanical properties,hardness test is usually used for drop forging.Today,we will introduce common hardness testing methods for closed die drop forging.

Both briness hardness and rockwell hardness are all the testing standard for drop forging hardness.Although the testing methods of them are not the same.But either of them can be adapted to see the hardness result of drop forging products.To ensure correct testing result,for one drop forging product,we should testing the hardness in different sections and check if heat treatment of drop forging is done in a good way.
Although the cost of drop forging dies may be relatively high,for piece price,it is very cost-effective.With drop forging process,the metal products can not only be in a low cost,but also win tough and durable characteristics.So that is why people say drop forging has low recurring cost and is the most beneficial production method for long runs.Of course,small quantities can be also offered,but more economocal with increased volume.Compared to cast or machined process,drop forging can produce metal products with a high strength-to-weight ratio.Also,it  has less chance of flaws and low injection rate.

So,when you are interested in sourcing for drop forging supplier.Fly Forge can be your one stop shop.Our quick turnaround times and impressed services are the best in drop forging industry.