Open die and closed die forging: Understanding the process

Metal is shaped by force during the forging process. After being heated to a specific temperature, the metal is worked into the correct shape. Open-die forging and closed-die forging are the two primary types of forging techniques. Understanding the distinctions between each method’s benefits and drawbacks will help you choose the ideal one for your particular requirements. Many websites provide open-die and closed-die services online. You can click on the link to learn about cxinforging in detail. Moreover, if you plan to use the services, always choose a reliable and trustworthy website to avoid inconvenience.

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Closed die forging

In the closed die forging process, sometimes called impression forging or press forging, the metal forms between two dies that enclose the forged object entirely. The metal is pushed between the two halves after being placed in a die, giving it the appropriate shape.

High-precision pieces and complicated forms are produced using closed-die forging. Because the dies can generate accurate designs with little waste, producing smaller, more intricate shapes is a more effective procedure. Forging in a closed die is frequently used for high-volume production, such as parts for the automobile or aerospace industries.

Open die forging

In the open die forging process, sometimes called free forging or smith forging, the metal is hammered or forced into shape between two flat or slightly curved dies that do not surround the forged material. The operator places the metal between the dies while blows from a hammer or press continually shape it.

Larger, simpler shapes like bars, rings, and cylinders are frequently produced using the open-die forging technique. It is also employed for bespoke shapes with little machining needed, making it a more affordable choice. The versatile open-die forging process can be applied to various materials, such as copper alloys, carbon steel, and aluminum.

The advantages and disadvantages of open-die and closed-die forging

Open and closed die forging each has unique advantages and disadvantages. Understanding these can help you determine the best method for your specific application.

Advantages of open die forging

1. Flexibility: Open die forging is a flexible process that can be used to create a wide range of shapes and sizes.
2. Cost-effective: Open die forging is a more cost-effective process for creating larger, simpler or custom shapes requiring minimal machining.
3. Greater size: Open-die forging can produce larger parts than closed-die forging due to the lack of constraint from the dies.

Disadvantages of open die forging

1. Reduced accuracy: Since the metal must be manually positioned between the dies during open-die forging, it is less exact than closed-die forging.
2. Waste: Because open die forging is less exact than closed die forging, there is more waste produced during the process.

Advantages of closed die forging

1. Greater precision: Closed-die forging is more precise than open-die forging due to the die’s exact shaping.
2. Efficient: Since the dies may be made to generate accurate designs with little waste, closed die forging is a useful procedure for producing smaller, more complex objects.
3. High-volume production: Closed die forging is typically used for high-volume production, making it a more cost-effective option for larger production runs.

Disadvantages of closed die forging

1. less options: Because each part requires a unique set of dies, closed die forging offers fewer options than open die forging.
2. More expensive: The price of designing and producing the dies makes closed die forging a more expensive procedure.

Applications of open-die and closed-die forging

There are numerous uses for both open-die and closed-die forging in numerous sectors. The automotive, electric vehicle, agricultural and forestry equipment, engineering and mining gear, hardware tools and fasteners, and electrical products and motors are just a few of the industries that CxinForging provides a wide range of forging solutions for. By offering hot forging, warm forging, and cold precision forging services, CxinForging can meet the specific requirements of each industry and provide high-quality components with great strength and wear resistance.

Every sector has unique specifications for parts and components, therefore it’s crucial to highlight that CxinForging’s capacity to offer tailored solutions helps them stand out in the market. Additionally, they may offer solutions for items that need minor deformations, high precision, and high-volume production by offering a variety of forging procedures.

Open die forging applications

Larger, simpler, or unique designs requiring little machining are frequently produced using open die forging. Typical applications include:

• Bars
• Rings
• Cylinders
• Shafts
• Flanges
• Discs
• Blanks

Open-die forgings are used in numerous industries for a variety of reasons, including mining, building, and energy.

Closed die forging applications

High-precision pieces and complicated forms are made using closed-die forging. Examples of typical applications include:

• Automobile components such crankshafts, connecting rods, and gears
• Components used in aerospace, like turbine discs and blades
• Components of industrial machinery, including bearings and valves
• Medical devices, such as implants and surgical instruments

In the production sectors of the automobile, aerospace, and medical industries, closed die forging is frequently employed.

Agricultural machinery and energy vehicles

The manufacture of agricultural machinery and new energy vehicles necessitates the use of parts that can bear extreme pressure and stress. For these industries, forged aluminium alloy offers high strength, durability, and corrosion resistance at a reasonable price. Forged aluminium alloy is frequently used for the following purposes:

• Automobile components include steering knuckles, engine blocks, and suspension parts
• Components for agricultural machinery, such as those used in combine harvesters, mulching and land-clearing tools, and machinery for processing waste wood.

Cold forging process in electrical products and motors

Without heating the metal, a method called cold forging is utilised to shape it, producing parts with better surface polish and dimensional accuracy. It is frequently employed in the production of components with intricate shapes and precise tolerances in the electrical and automotive industries. Cold forging is frequently used for the following purposes:

• Rotors and shafts for motors
• Electrical connectors and terminals
• Heatsinks and radiators
• Copper terminals for electronic devices

Conclusion

Metal can be shaped by exerting force using two forging techniques: open-die and closed-die forging. Knowing the benefits and drawbacks of each approach will enable you to choose the one that will work best for your particular application. While closed-die forging is used to produce complex forms and high-precision parts, open-die forging is often utilised for larger, simpler shapes or custom shapes that require little machining. Both approaches have numerous uses in a variety of industries. CxinForging is prepared to fulfil the specific demands of its clients and offer them the appropriate solutions to advance their operations thanks to a focus on quality, accuracy, and innovation.

This is a detailed guide about open die forging and closed die forging, including technical drawings and the direct comparison of these two different techniques.

Steel Available can help you source Steel Forgings

As we saw in the earlier article “The History of Steel Forging” the forging industry in the past was completely upside down. The techniques were different, the processes were inefficient, and the applications were bizarre! Although the techniques lead the way to advancements in future, a lot of changes were needed to bring efficiency in the process.

However, in the modern society, forging engineering is involved in numerous industries like construction, machinery, agricultural, automotive, oilfield equipment, and more. More the consumption, more the advancement and increase in number of techniques!

Steel billets can be processed and fabricated through various forging processes. Among the widely applied metal forging techniques is the closed die forging and open die forging. Although these two types of forging methods belong to the forging basics, it is not so difficult to point out the differences between the two.

Let us have a deeper insight into the differences between open and closed die forging!

Open Die & Closed Die Forging Processes in Comparison

Open and Closed Die Forging Processes in Comparison

Original Source: Suranaree University of Technology

The Description

Open die forging process is also known as free forging. The piece of metal is deformed between multiple dies that do not enclose the metal entirely. The dies hammer and stamp the metal through a series of movements to alter its dimensions until the desired shape is achieved.

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Closed die forging process is also referred to as impression forging. It utilizes pressure to compress the metal piece to fill an enclosed die impression. A medium frequency induction heating furnace is used to heat the metal to get the desired shapes.

The Process

The technique of both open die forging and closed die forging is different. In general, for closed die forging, the molding dies are first made. The metal bars are then placed on the dies and forged to any shapes that are desired.The closed die forging technique utilizes very less or no machining throughout the process. Also, net shape end products can be achieved.

For open die forging, enormous compressive forces are imposed by the continuous strike of a forging hammer to deform the metal billets. Go through the image illustration of the open die forging process here.

Interested in a short visual documentary on the open and closed die forging processes? Check out the forging process video:

The Forging Process of open die and closed die forgings

Source: Youtube

The Application

The forged components obtained by open die forging and closed die forging, if compared, are not identical in their application scope. Usually, the metals become stronger and tougher after the forging process due to the modification in its internal grain structure.

A rough precision machining is further required after the open die forging process as imprecise dimensions are achieved by hammering. The open die metal forge parts are more suitable for large parts in a number of tons. Generally, the products in this category of forging include forged long shafts, forged rollers, and forged cylinders. They are mostly utilized in the railway and the aircraft industry.

However, for small parts, closed die forging is preferred as high precision is obtained in the process. It is highly used to produce forged fittings, forged flange, forged automotive parts, etc. Oilfield, automotive, and mining are some of the industries that rely on closed die forge parts.

The Benefits & The Drawbacks

Advantages & Disadvantages

List of References:

[1] – http://www.canforge.com/open-die-forging/

[2] – http://www.ferralloy.com/open-die-forging-explained/

[3] – http://www.dropforging.net/closed-die-forging.html

[4] – http://www.ferralloy.com/closed-die-forging-process-applications/

[5] – http://www.scotforge.com/Why-Forging/Forging-101/Open-Die-Forging

If you want to have more information about the article or you want to share your opinion with us, contact us at .

Please notice that you might be interested in the other technical articles we’ve published:

  • What is Steel Forging?

  • The History of Steel Forging

  • Hot Rolled Steel, Cold Rolled Steel & Cold Drawn Steel – What’s the difference?

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