Composite Die Forging Technology
Composite die forging is an advanced forging process which has been increasingly employed in the production of complex parts. It is a type of open-die forging involving two tools: a male die and a female die. Composite die forging is capable of producing a wide variety of near-net-shape parts with superior edges and surfaces, among other advantages. The process typically involves multiple stages of forging, each stage typically accommodating a different toolset for shaping and refining the forgings. Many complex parts can be forged in one pass which reduces the need for secondary operations, resulting in significant cost-savings.
The basic components of a composite die include a blanking die and a forging die. The blanking die is typically cylindrical in shape and is used to transform the raw material into a desired shape or profile. It is typically consisited of a tool set, generally referred to as the upper die, and a base plate, generally referred to as the lower die. The upper die is typically the stationary part and may be in the form of anvils, die blocks, or dies. The lower die is the mobile part and may be in the form of a bolster, a slide, or an arbor.
The forging die is used to refine the shape and size of the forgings. It consists of two major components: a front die, also known as the die half, and a rear die, also known as the punch half. The front die is the longer of two dies, and it typically includes a tapered drum, several anvils, or a combination of the two. It is the section of the die with which the raw material moves into contact during the forging process. The rear die is the shorter half, and it generally consists of a plunger or a ram which is used to drive the forging process.
The process of composite die forging involves the parts placed into a press and brought into contact with the male die and female die. These dies are then subjected to tremendous pressure from the press to shape and refine the parts. This pressure is usually transferred from the lower die to the upper die. The parts then move through the upper and lower dies in order to achieve the desired shape and size of the part. The material is then eliminated from areas not desired, such as corners and edges. This process is repeated multiple times until the desired size and shape of the part is achieved.
Composite die forgings can be created with complex shapes which require minimal cleaning and finishing and have improved mechanical properties over other forgings. The process has a wide range of applications, such as in the automotive, aeronautical, and military industries. It can also be used to create products as diverse as vehicle and aircraft structures, bearings and gear blanks, and blade holders. Composite die forging has become a popular technique due to its ability to provide complex shapes with superior edges and surfaces, and it creates cost-effective and reliable components in a wide variety of applications.
