Die forging is a metal forming process through which the molten metal is heated and then put under the pressure of a die forging die to shape a given part. Typically, die forgings involve two or more dies. The first die is used to shape the material; the second or subsequent dies are used to add texture or other features. Die forging can be used to create parts for a variety of applications including automotive components, aerospace components, medical parts and even industrial machine parts.
Die forgings have many advantages over other metal forming processes such as EDM and CNC machining. Die forged parts are much stronger than those created by EDM or CNC machining because they are able to withstand greater amounts of stress and force. This increased strength is also beneficial for safety, as die forgings can absorb and dissipate energy much more heavily compared to parts from CNC machining or EDM. Die forged parts are also cheaper than those created by these other techniques, as the cost of the material, the necessary dies and the process itself is typically lower.
The die forging process begins with the selection of a die. Dies come in many different shapes, sizes and designs. An industrial die contains all of the features necessary for the given part, including an outline shape and any textures, fluting or machining operations. The selection of a die depends on the desired shape and features of the finished part. Once the appropriate die has been chosen, the metal is heated until it reaches a liquid state and then placed into the die cavity.
Following the insertion of the metal, the die is closed and forced together under extreme pressure. The pressure of the die forces the material to fill the die cavity and take the form of the chosen die. The finished result is a part that has a greater degree of details and strength than if it was produced by other forming processes.
After the part has been created, it is machined to its finishing specifications and cooled. Once the part has cooled, it is ready for assembly. Die forgings are typically used for the production of parts with complex shapes, tight tolerances, excellent surface finishes and great strength. Die forgings can be used to make a wide variety of components, from small components to large structural parts.
Overall, die forging is a great way to create strong and enduring parts in a relatively cost effective way. With the proper selection of a die, the process is relatively quick and the results can be impressive. Die forging is also advantageous for applications that require light weight components, as well as for high wear or high-performance parts. Die forging is a great method for creating a wide range of components, and it is becoming increasingly popular among manufacturing operations worldwide.
