What is open die forging?
A wide-range of open die forgings are offered here at Somers Forge. Open die forging is the process of shaping heated metal between a top and bottom die using force. The term open die gets its name from the work-piece not being enclosed. With each continuous strike of the metal, it is gradually shaped to the required dimensions increasing the strength and grain structure.
Items are manipulated at high temperatures normally ranging from 1200 -1280 degrees centigrade. However, it is not possible to form high precision parts from just the forging process alone; the machining of products after forging is often required to achieve the desired finish. Our unique forging equipment is capable of forging close tolerances to minimise the amount of machining required on a finished part. In-turn, this helps to minimise tooling costs, making open die forging more cost-effective.
Closed die forging on the other hand has dies which are specifically shaped to the desired configuration, resulting in high costs to make the tool mould before adding on the forging cost itself. The open die forge does not enclose the metal completely and therefore allows different dimensions to be created with greater properties/scope unbeatable grain structure.
What types of applications are best suited to open die forging?
Open die forging is best suited to large pieces used for short runs. These mostly consist of forged bars, blocks, shafts, cylinders, discs, hubs, flanges and custom forged shapes. Most popular applications are often single runs or bespoke designed items. Its versatility in shaping custom and large-scale components therefore makes it the preferred choice for industries requiring flexibility and adaptability in their manufacturing processes.
What is the difference from closed die forging?
Closed die forging, also referred to as impression die forging, encompasses the process of shaping metal within enclosed dies as opposed to open dies. Precision machining of the moulding dies in closed die forging incurs high initial expenses. Although closed die forging excels in crafting intricate parts with tight tolerances, open die forging is favoured for small runs and one-off pieces.
What are the benefits of open die forging over closed die forgings?
The biggest advantage of open die forgings is their incredible strength, creating hard-wearing, durable products with an excellent surface finish. Open die forgings’ particular strengths lie in:
- Bespoke short runs
- Improved microstructure
- Greater strength
- Better fatigue resistance increasing the lifespan
- Finer grain size
- Shaping reduces the voids
- More economical
- Less material waste
By subjecting the metal to repeated pressure, the process enhances structural integrity and grain flow, thereby reducing porosity and improving strength, durability, and fatigue resistance. Moreover, open die forging offers quick lead times, making it economically viable for various industries without the need for bespoke tooling.
Open die forging materials
We forge a large range of materials including:
- Carbon steel
- Alloy steel
- Stainless Steel
- Inconel
- Titanium
- Tool steel
- Aluminium
- Copper
- Nickel
- Bronze
Why Somers Forge for Open Die Forging Solutions?
At the core of Somers Forge is an unrivalled commitment to precision and detail. Whether it’s a specialised part, a limited edition run, or a product requiring specific characteristics, we are experts at tailoring solutions to the individual needs of our customer base spanning many different industries. Our team of seasoned and skilled professionals, dedicated to the perfection of their craft, ensure that every product is forged to meet exact specifications, making us the premier destination for all your open die forging solutions.
For further information or for a quotation on open die forging today, contact us by calling 0121 585 5959 or filling out our online enquiry form below.
