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Key Considerations in Closed Die Forging

Closed die forging is a forming process that uses specialized tools called dies to shape metal into the desired form. This technique has many advantages over other metal forming methods, including increased strength and precision of the finished product. Thus, it is widely utilized in the automotive, aerospace, and energy industries.

Depending on the component’s complexity, the forging process may involve multiple phases. The metal is subjected to high pressure at each stage to form a particular shape while repeatedly altering the grain flow and microstructure.  As a result, the final product has enhanced mechanical properties and increased strength compared to the original material.

Closed die forging is highly specialized, requiring a deep understanding of the material and the ability to control multiple variables to achieve the desired results. Here are four of the most important factors you need to consider:

Material

The metal used for forging must have the right strength, toughness, and ductility to withstand the high compressive forces of the process. Some examples of metal for closed die forging are as follows:

• Aluminum: This is a versatile material well-suited for closed die forging, providing a balance of strength, weight, and durability. However, it has a low yield strength, so the forging process must be carefully controlled to ensure it is not overstressed.
• Carbon Steel: While more prone to corrosion and may be brittle at low temperatures, carbon steel has good forgeability. It is also relatively cheap and can be heat-treated to enhance its strength and hardness.
• Alloy Steel: This is often forged to produce components for high-stress applications like gears, crankshafts, and axles. It also offers high strength and improved resistance to wear and corrosion.
• Copper Alloy: Its high conductivity makes it ideal for forging electrical components, such as connectors and terminals. It also has exceptional strength and durability for high-stress applications.
• Titanium: Due to its low melting point, titanium is suitable for producing complex, highly precise shapes. However, it is significantly more expensive than other metals.

Die Shape

In closed die forging, the die’s shape determines the product’s final look. Therefore, it must closely match the desired configuration of the workpiece to ensure that it is properly formed. It must also be designed to accommodate the specific material properties of the metal being used, such as its strength and ductility.

The material will be overstressed if the dies are too small or do not provide sufficient clearance for the material to flow. This will lead to cracking, warping, or other defects. Meanwhile, if the dies do not match the desired shape, the product will have inconsistent dimensions or be out of tolerance.

Forging Load

The forging load determines the amount of pressure applied to the metal during the process. Therefore, it is essential to ensure that the correct pressure level is used to produce a strong, durable component.

If the forging load is too low, the metal will not be ductile enough to take the shape of the dies. This results in a weak and low-quality product. Conversely, the metal will be overstressed if it is too high, leading to cracks, deformations, or other flaws.

Heating and Cooling Cycle

The heating and cooling cycle refers to warming the metal to a high enough temperature to make it malleable or plastic. Then, it will be cooled to solidify it in its new shape. The metal will crack if it is rapidly cooled and become too porous if it is cooled too slowly.

High-Quality Closed Die Forging With Cornell Forge

At Cornell Forge, we utilize a diverse range of forging methods to manufacture high-performing steel components that can handle even the toughest industrial conditions! Our expertise lies in manufacturing custom-made steel parts using premium quality stainless steel and steel alloys. Moreover, we offer value-added services like assembly and heat treatment to guarantee that each product is perfectly suited for its application.

Contact us to learn more about our services!

What To Look For in Your Stainless Steel Forging Manufacturer

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Stainless steel is utilized in various industries and is most sought-after in forging applications. Alloy forgings are designed to be extremely durable and resistant to corrosion and heat. Thus, stainless steel’s best properties — corrosion resistance and strength — are leveraged and magnified by forging.

As the demand for stainless steel grows, the number of companies offering stainless steel forging services is bound to increase. However, this high-precision process requires a high level of manufacturing expertise and experience. Hence, you must consider several factors when choosing the best forging manufacturer.

Stainless Steel Forging and Its Applications

Since forging produces grain flow that conforms to the shape of the workpiece, stronger items can be produced by forging than by other techniques like machining or casting. In addition, stainless steel is strengthened and made more durable during the forging process, creating robust components ideal for harsh environments or applications.

Alloys made of stainless steel often have chromium as a secondary component, making up between 4% and 30% of the alloy’s overall composition. In addition, carbon, aluminum, titanium, copper, nickel, and other elements are frequently included in these alloys.

Several types of industrial-grade stainless steel alloys are utilized in various applications, including the following:

• Architecture and construction
• Chemicals and pharmaceuticals
• Energy and industry
• Medical equipment manufacturing
• Shipbuilding and marine engineering

Qualities of a Good Stainless Steel Forging Supplier

To determine whether a steel forging company is the best partner, it’s crucial to consider product quality, price, availability, dependability, and customer service. Other qualities you should look for include the following:

High Level of Standards Compliance

A reliable steel forging supplier can deliver custom services compliant with industry standards. They must offer competitive prices while delivering unmatched, high-quality, and undamaged products on time. Working with someone capable of doing all these helps increase your manufacturing ROI and streamline your operations.

Effective Collaboration Skills and Processes

Constant and clear communication with a forging company saves you time, minimizes errors, and allows adjustments in areas and circumstances that require it. It also ensures that you receive your orders on time and with the highest quality, avoiding delays in your production. A forging provider that respects your time restrictions and deadlines can also save you a lot of money in the long run.

Proficiency and Industry Expertise

The ideal steel forging provider can serve as a resource for information and advice. For instance, they can assist clients in evaluating new production techniques, such as switching from casting to forging, where applicable. When relationships are built and nurtured to this level, you are guaranteed consistent, reliable, and high-quality components every time.

Cornell Forge: The Right Stainless Steel Forging Manufacturer for You!

Cornell Forge is an ISO 9001:2015 and PED certified business that exceeds customer expectations with dedicated and high-quality work at every production level — from RFQ to the order’s delivery! Our team has a wide range of capabilities for your most challenging stainless steel forging needs.

Contact us to start working with our forging experts today!