What Are the 4 Types of Forging?

Forging is a metalworking process that involves shaping metal by applying compressive force. This process can be used to create a wide range of parts and components for various industries, including automotive, aerospace, and construction. There are several types of forging, each with its unique characteristics and applications. Here, we will explore the four main types of forging: open-die forging, closed-die forging, impression-die forging, and roll forging.

1. Open-Die Forging

Open-die forging, also known as smith forging, is the simplest and most versatile type of forging. In this process, the metal is heated to a high temperature and then placed between two flat or shaped dies. The dies are then pressed together, causing the metal to deform and take on the shape of the dies.

Open-die forging is ideal for producing large, irregularly shaped parts such as shafts, axles, and forgings for large machinery. Since the dies are not fully enclosed, the metal can flow freely, allowing for more complex shapes to be formed. However, open-die forging typically requires more manual labor and is less precise than other types of forging.

2. Closed-Die Forging

Closed-die forging, also known as impression-die forging or die forging, involves using two dies that fully enclose the metal. The metal is heated and placed between the dies, which are then pressed together to shape the metal.

Closed-die forging is highly precise and can produce parts with tight tolerances and complex shapes. It is often used to produce smaller, more intricate parts such as gears, bearings, and connecting rods. Closed-die forging requires specialized equipment and skilled operators, making it more expensive than open-die forging.

3. Impression-Die Forging

Impression-die forging is a type of closed-die forging where the dies are designed to create specific impressions or features on the surface of the forged part. This process is often used to produce parts with intricate details or textures, such as automotive wheels or decorative hardware.

Impression-die forging combines the precision of closed-die forging with the ability to create unique surface features. It requires highly skilled operators and precise die design to ensure that the desired impressions are accurately formed on the part.

4. Roll Forging

Roll forging is a continuous forging process where the metal is passed between two rotating rolls. The rolls are shaped to deform the metal into the desired shape, similar to how a pasta machine shapes dough.

Roll forging is ideal for producing long, continuous parts such as bars, shafts, and pipes. It is highly efficient and can produce parts at a high rate, making it suitable for mass production. Roll forging can also be used to reduce the thickness of metal sheets or to create specific shapes along the length of the part.

Conclusion

Each type of forging has its unique advantages and applications. Open-die forging is versatile and suitable for large, irregularly shaped parts, while closed-die forging offers high precision and is ideal for smaller, more intricate parts. Impression-die forging combines the precision of closed-die forging with the ability to create unique surface features, and roll forging is efficient and suitable for mass production of long, continuous parts. Understanding the different types of forging can help you choose the best process for your specific application.