Die forging is a process of plastically deforming the billet in the die cavity by using a die to obtain a forging with a specific shape, size, and mechanical properties. Die forging is the most widely used type of forging process. Die forgings are also widely used. Die forging can not only complete the processing of forgings directly but also can be combined with other forging methods such as hot forging, free forging, and roll forging to form a new forging process so that forgings with more complex shapes and better mechanical properties.
We can classify according to the structure of the forging die: the first type is that there is a burr groove on the forging dies to accommodate excess metal, which is generally called open die forging; there is no burr groove on the forging dies, we call it Closed Die Forging. The names of these two die forgings are common, and we have introduced them in more detail. If you want to know more, you can click on the articles on Open Die Forging and Closed Die Forging.
We can also divide die forging into hot die forging, warm forging, and cold forging according to the temperature of the forging billet. Hot die forging is heating the forging billet above the recrystallization temperature and then placing it in the forging die to forge the required workpiece. Warm forging is heating the forging billet between the recrystallization and the recovery temperature and then putting it in the forging die. Cold die forging is die forging completed below the recovery temperature of the forging billet. We need to choose the appropriate forging billet temperature according to the mechanical performance requirements of the forging. If you have drawings and need OEM services, you can contact HULK Metal because we have advanced forging factories that can complete your forging order faster under the premise of ensuring quality.
We can also divide die forging into Precision Die Forging according to the forgings' precision, which is a forging process that can directly complete forgings on die forging equipment. The forgings can be used without or with little finishing. The dimensional accuracy of precision die forgings can reach IT12~ITl5, and the surface roughness Ra is 3.2～1.6μm.
We can divide die forging into hammer die forging, crank press die forging, flat forging machine die forging, and friction press die forging, according to different equipment.
We can also divide die forging into single-cavity die forging or multi-cavity die forging according to the process of billet forming. The direct forming of the forging billet in the die cavity is called single-cavity die forging. Forgings with complex shapes that need to be performed in several steps are called multi-cavity die forging.
Die forging is the most commonly used one of the forging processes. We can use die forging to process carbon steel and alloy steel with various components, followed by aluminum, magnesium, copper, titanium, and their alloys. Different materials have different physical and chemical properties. We need to choose the appropriate die forging to process to obtain forgings with specific properties. If you have drawings, you need to select a more professional forging factory to provide you with OEM services. You can learn about HULK Metal.
l High production efficiency and low labor intensity;
l The forgings produced are accurate in size and have low machining allowances;
l Forgings with complex shapes can be forged;
l Suitable for mass production.
l The forging flow lines inside the forging are distributed according to the contour of the forging so that the forging has better mechanical properties and longer service life.
l Simple operation, easy mechanization, and high productivity.
l The cost of the mold is high, and special forging equipment is required, which is not suitable for single-piece or small-batch production.
The forgings for general industry, forgings for hydroelectric generators, forgings for thermal power stations, forgings for metallurgical machinery, forgings for pressure vessels, forgings for ships, forging machinery and equipment, forgings for automobile industry, forgings for locomotives, forgings for the military.
All the above forgings can be produced by die forging.
The production of die forgings needs to formulate the forging process according to the requirements of forgings. For some forgings, die forging can only be carried out after heating the forging billet above the recrystallization temperature and then performing. Forging companies will formulate complete production solutions according to the forgings drawings. The production of die forgings requires high mold costs and is more suitable for mass production. If you only customize one or a few items, you can choose other forging methods.
1. Draw forging drawings;
We first need to use drawing tools such as CAD to draw drawings of die forgings according to the shape, size, and other elements of the forgings. This will facilitate subsequent mold-making.
2. Formulate the production process of forgings;
After drawing the drawing, we need to choose the appropriate performing, die forging, finishing, and other processes according to the requirements of the forging so that the order can be completed more efficiently.
3. Quality control;
A forging company with excellent service capabilities will have a professional quality control team and advanced quality inspection instruments and set up inspection points during the production of forgings (generally, various parameters of raw materials, semi-finished products, and finished products will be tested). They will ensure that the quality of forgings meets the requirements, improve the yield of orders and shorten the production time of orders.
4. Raw material procurement and testing;
We will screen several raw material suppliers and start purchasing after confirming that the physical and chemical properties of the raw materials meet the standards. Professional forging factories will strictly test each batch of raw materials to ensure the quality of products from the source.
5. Forging Billet Blanking;
Cut raw materials to specific sizes. There are many ways to cut the bar stock, such as punching and sawing. Use which blanking method depending on the forging process and the factory's production capacity.
6. Forging Billet Pretreatment;
Hot die forging and warm die forging require heating the forging billet to a specific temperature. Contact electric heating also needs trimming of the forging billet.
7. Die Forgings Pre-forming;
Use free forging, roll forging, die forging, and other processes to process the ingredients into a specific shape and then put them into the forming forging dies. This lets the billet fill the cavity better.
Put the preformed billets on the mold and press them into the mold. According to the characteristics of the mold, forgings with or without flash can be obtained; if it is precision die forging, a formed forging can be obtained at one time.
9. Finishing Process to be a finished product;
After the finishing process, removes flashes, burrs, etc., and then through CNC Machining and surface treatment to obtain the final product.
10. Packaging and Warehousing;
After the finished product is produced, it is packaged according to the requirements. The packaged goods will be placed in the warehouse, waiting for delivery.
There are many delivery methods, such as FOB, CFR, and so on, and most companies support all delivery methods. An experienced forging company will have a professional freight team to provide freight consulting services.
12. After Sales Service.
A responsible forging company will provide comprehensive after-sales service to guarantee product quality. HULK Metal will provide return, replenishment, and exchange services for each customer and actively communicate with each customer to negotiate a perfect solution.
The above is the process used by die forging factories to provide customers with die forging services.
An excellent die forging factory not only has a variety of equipment to complete free or die forging and so on but also has an advanced quality control center to ensure that each product's quality can meet customer requirements. Companies that can provide excellent die forging services generally supply complete production solutions. We can choose a company with a more suitable price and complete solutions through multiple comparisons as a later service provider. When comparing the solution provided by die forging companies, we can start from the following 6 points.
1. Can the die forging service company's technical team works out a production solution faster based on the drawings or samples you provide?
2. Comprehensively score the price, quality, production cycle, delivery method, payment method, and so on of the completed order, and select the top three companies with higher scores as choices.
3. Whether the factory has sufficient production capacity. It is possible to provide a video to see the factory when it is not easy to visit factories on the spot.
4. The time for the factory to complete the production of the order, the experience of the production team, the quantity of equipment, and the quality inspection service are all factors that can be considered.
5. Whether they have enough freight capacity. If they have enough shipments, they can get more freight discounts and get a more suitable freight price for you.
6. Whether it can provide quality assurance service. They can propose a better solution centered on you when there are quality problems with the product.