What tooling do you use for closed die forging?

The tooling used in closed die forging is critical to achieving precise and durable parts. The tooling typically consists of several components designed to shape, control, and process the material effectively during the forging operation. Here's an overview of the main tools and their functions:

1. Forging Dies

The most critical component of the closed die forging process:

• Upper Die and Lower Die: These dies contain the cavities that shape the heated billet into the desired part.

• Flash Land: A narrow, flat area around the die cavity that controls material flow and flash thickness.

• Gutter: A recess outside the flash land to collect excess material (flash).

• Cavity Design: The die cavities are machined to the exact dimensions of the part, including allowances for shrinkage and machining.

• Material: Dies are typically made from high-strength tool steels or other alloy steels capable of withstanding high temperatures and pressures.

• Die Features:

2. Punches

• Purpose: Used to create holes, indentations, or other features in the forged part.

• Material: Made from the same high-strength materials as the dies to resist deformation and wear.

3. Die Holders

• Function: Secure the upper and lower dies to the forging press.

• Design: Die holders are designed to align the dies accurately and ensure consistent forging pressure.

4. Forging Press or Hammer

• Press Types:

• Mechanical Presses: Use mechanical linkages to apply force.

• Hydraulic Presses: Use hydraulic pressure for precise and controlled forging.

• Drop Hammers: Use gravity and high-speed impact for forging.

• Purpose: Provides the force required to deform the heated billet into the die cavity.

5. Trimming Tools

• Purpose: After forging, trimming tools are used to remove the flash (excess material squeezed out of the die cavity).

• Components:

• Trimming Die: Matches the forged part’s profile to trim the flash accurately.

• Press or Shear: Equipment used to apply the force needed for flash removal.

6. Lubrication Systems

• Purpose: Apply die lubricants to reduce friction, improve material flow, and minimize wear on the dies.

• Types:

• Spray systems.

• Manual application tools.

7. Heating Equipment

• Purpose: Heats the billet to the required forging temperature (e.g., 1,100–1,300°C for steel).

• Types:

• Furnaces.

• Induction heating systems.

8. Gauges and Inspection Tools

• Purpose: Used to verify the accuracy of the forged part and ensure it meets dimensional and quality specifications.

• Examples:

• Measuring gauges.

• Coordinate Measuring Machines (CMM).

• Surface finish testers.

9. Tooling for Die Maintenance

• Purpose: Maintain and repair dies to extend their life and ensure consistent part quality.

• Examples:

• Grinding machines for refurbishing worn die surfaces.

• Welding equipment for repairing cracks or defects.

10. Auxiliary Equipment

• Billet Cutting Tools: To cut raw material into appropriate sizes for forging.

• Transfer Systems: To handle billets between heating, forging, and trimming stations.

• Cooling Systems: For cooling the dies and forged parts after processing.

Summary of Tooling Components:

Efficient use and maintenance of these tools are vital to ensure productivity, precision, and durability in closed die forging operations.