OPEN AND CLOSED DIE

FORGING PROCESS

Deepesh
AI-DS (T)
FORGING PROCESS
Forging is a manufacturing process where metal is shaped by
applying compressive forces.
The metal is heated until it's malleable, and then it's hammered
or pressed into the desired shape. Forging can make the metal
stronger and can also create complex shapes that are hard to
achieve with other methods. It's used to make things like
industrial machinery parts, tools, and automotive components.
• The two broad categories of
Forging processes are,

1. Open Die Forging Process(free forging, or

smith forging)
2. Closed Die Forging Process(Also called
impression forging)
OPEN DIE FORGING
Open die forging is carries out between
two flat dies or simple shapes. This
process is used mostly for large object
and smaller quantities It is also used to
preform the work piece for closed die
forging.
OPEN DIE FORGING
straightforward process:
1. You take a metal billet heated to extreme temperatures (1900-2300 degrees Fahrenheit).
2. Place the material between the dies along the direction of the grain lines to ensure it
stays strong and doesn't break during the open die process.
3. A 'fuller' tool helps divide the metal piece into smaller sections, making it easier to work
on one area at a time.

4. The dies compress the metal, or “hammer” it into shape as the metal adapts to the
pressure.
OPEN DIE FORGING
• ADVANTAGES
1.Improved Strength: Open die forging enhances the strength and structural integrity
of the metal, leading to superior mechanical properties in the final product.
2. Flexibility and Customization: This method allows for the production of large,
custom-shaped parts with well cut grain structure, making it highly flexible for diverse
manufacturing needs.
3. Cost-Effective for Small Runs: Open die forging can be cost-effective for small
production runs and prototypes, as it doesn't require expensive tooling or molds,
making it ideal for shorter production runs.
OPEN DIE FORGING
• Disadvantages of Open
Die Forging

1. Not Suitable for Precision Parts.

2. Process Required Machining (Since open die forging often produces irregular shapes, in most
cases there post-machining is required to finish the product into the desired part.)
3. Inconsistent Results
4. It is risky to do mass production as the level of irregularity may increase, leading to losses.
OPEN DIE FORGING
LIMITATIONS

Simple shapes only; difficult to hold less tolerances

,machining necessary; low production rate; poor
utilization of material; high skill required
CLOSED DIE FORGING
closed die forging is very similar to open die
forging, except that the dies are custom made in
specific shapes and the metal is closed-fitted
within the dies. The work piece is deformed
between two die halves which carry the
impressions of the desired final shape It uses
carefully machined matching die blocks to
produce forgings to close dimensional tolerances,
Normally used for smaller components.
CLOSED DIE FORGING
• FLASH
Flashing refers to the unwanted material that was
not used to create a part during the forging
process. This material usually overlaps and
exceeds the required dimensions and is usually
removed by machining after completing the
forging process. The below shows the flash
formed when a force F is applied to the metal
billet.
CLOSED DIE FORGING
• Purposes Of Flash
1. Ensures Complete Filling of Die Cavity
2. Regulates Metal Flow
3. Protects Die Surfaces
4. Facilitates Trimming and Finishing(Flash provides a convenient location for trimming and
finishing operations, allowing for precise removal of excess material and achieving the
desired final shape of the forging.)
5. Recyclable Material
CLOSED DIE FORGING
• The forging pressure is inversely proportional to the flash thickness
and directly proportional to the flash width. This means that as the
flash thickness decreases, the forging pressure increases, and as the
flash width increases, the forging pressure also increases.
• Advantages of Closed Die
Forging
1. High Strength
2. Close Tolerances
3. The forging is close to the perfection or actual measurements that no extra work is
required to be done after the process.
4. No Material Limitation (Closed die forging operations use a wide range of material
types from steel, brass, aluminum, iron, and other metal alloys.)
5. Better Surface Finish
 Main Differences Between
Open and Closed Die Forging
OPEN DIE FORGING
1. The method works by compressing the
workpiece between the two flat dies.
2. The cost of the die is low.
3. The is poor utilization of the material
during the process.
4. The products often come out with poor
dimensions and irregularities.
5. The process is mainly used for producing a
few products.
CLOSED DIE FORGING
1. The method works by compressing the
workpiece between the two impressed
dies.
2. The cost of the die is high.
3. The is effective and conservative
utilization of the material during the
process.
4. The products often come out with precise
dimensions and low tolerances.
5. The process can be used for mass
productions.