Open die forges refer to the shaping of hot metal pieces on a mandrel before they are struck off. The piece is fed with molten zinc or tin and the metal piece is allowed to pass through a die, shaped by a tooling die. A workable design is created when the piece strikes off the mandrel at the base of the tooling die. The entire procedure of forming the metal into the desired shape takes place in less than one minute.
Open die forgers use a standard machining process called rolling. Rolling can be used to form a wide range of products such as wheels and castors. It can also be used to obtain desired shapes such as round, cylindrical or ovular shapes. High grain flow, low porosity and high tolerance are some of the mechanical properties of the product of Open Die Forging.
Open Die Forging uses an extremely simple and energy-efficient design. Cylindrically shaped pieces can be made using the Open Die Forging technique. Shaped pieces produced by using this technique include all facets and all flat faces. In addition, it can be used to obtain numerous rounded or angled shapes. Shapes obtained using this method include boxes, tubs, tubes, conical shapes, domes, bowls and curved surfaces.
Forged carbon steel has inherent advantages over other forms of fabrication. Forged carbon steels have better tensile strength and than conventional cold rolled steel. Moreover, carbon steel tools used in the Open Die Forging process generate more heat faster and produce a higher quality of formed cutting edges. The carbon steel tooling also engenders a better performance from the cutting edges than other machining operations.
Anvils used in the Open Die Forging process are made out of diamond or graphite. A good quality diamond is essential for ensuring that the tooling is strong and that the tool can strike the anvil with the right force. The graphite used as an anvil is usually titanium or aluminum and has a higher density than graphite anvils used in closed die forging. This enables the anvil to be effectively struck by the hammer as well as it can hold a bigger impact than other kinds of anvils.
Although the production of carbon steel in the forge anvil process is simple and inexpensive, the durability of the finished product depends on the skill of the anvil smith. The number of rolling cycles, feed rates and speeds during which the roll forming operation is carried out play a pivotal role in determining the end product. To ensure consistent quality, the manufacturer should ensure that he follows the basic guidelines like the consistent, fine grain flow, high tolerance, and consistent hammer force. Each of these features will help to ensure that the final products are durable and reliable.
