Hilton Roll Forging Methods
The Hilton forging method, also known as forward slip forging, is an advanced forging process aimed at the production of high quality components with tight tolerances. It is a form of traditional forging and uses less than a third of the energy used in traditional forge methods. This is due to the fact that each stroke of the hammer is geared to produce directional deformation, which reduces the amount of energy needed to shape the material.
Hilton roll forging is mostly used to reduce the weight and surface area of components. This helps to reduce waste and cost, while improving their mechanical qualities such as strength and ductility. The process is most often used to create parts with a particular profile, such as gear teeth or splines, which require finely detailed surface finishes.
The Hilton forging process begins with the placement of a hot, uniformly heated billet, into the tooling on a press. The press then slowly applies a load which deforms the surface of the billet and begins to shape the component according to the predetermined metallurgical and geometrical design.
Hilton forging press is capable of forging all sorts of materials including stainless steel, heat-treated steel and superalloys. The press provides a powerful and efficient way to achieve complex parts for mass production. The press consists of a hydraulic or mechanical system that acts as the driving force, a heated billet holder with a single fixed die and two rotating dies, die-holders and a pair of rollers.
The rollers are actuated by a hydraulic piston-operated system, and they rapidly traverse the surface of the heated billet while pressing it against the self-inflating die holders. On the surface of the billet, the rollers cause localized plastic deformation along the contours of the part being forged.
The rotor and die-holder rotators perform two functions. The first is to inject lubricants, such as coolant and cutting oils, into the contact area between the rollers and the billet leading to cooling of the operative area. The second is to inject pressurized air or nitrogen, to reduce air friction and improve the cooling of the workpiece.
Once the desired form is reached in the desired alloy, the pressure is released and the part is removed from the tool. The surface finish will be very accurate and can reach a surface quality of 0.032micron RMS on very delicate parts.
The Hilton method is an extremely efficient and cost-effective means of creating metal components. With its two stage cycle, the process is twice as fast as traditional forge methods and utilizes far less energy. The use of this method allows for advanced microstructural changes to be made to components, which can have a significant impact in the physical properties and metallurgical performance of the part. This, coupled with its ability to produce high quality parts with stringent tolerances, makes the Hilton forge method an ideal solution for all of your forging needs.
