1. Definition
Open forging is a processing method that uses impact force or pressure to make metal deform freely between the upper and lower anvil surfaces, and obtains forgings that no restrictions on shape, size and certain mechanical properties.
2. Classification
(1). Manual open forging: It mainly relies on simple manpower tools to forge the blank to change the size and shape of the blank to obtain the required forging. This method is mainly used to produce small tools or utensils.
(2) Machine open forging: mainly relies on special forging equipment and special tools to forge the blank to change the size and shape of the blank to obtain the required forgings. Machine can be divided into two types: forging hammer and press open forging according to the type of equipment used.
a. Forging hammer is used to forge small and mediumsized.
b. Press is mainly used to forge large products.
3. Basic process flow
Upsetting: During the forging process, the height of the blank is reduced and the cross-sectional area is increased. It is mainly used for forging gear blanks, round cake forgings, etc.
Drawing out: also known as eye extension, a forging process that reduces the crosssectional area of the blank and increases the length. Mainly used for forging rods and shaft forgings.
Punching: the process of forging a through hole or a semithrough hole on the blank
Bending: the process of bending the blank into a specified shape
Twisting: the auxiliary process of rotating one part of the blank relative to another part around an axis
Cutting: the auxiliary process of cutting or partially separating the blank
Shifting: the auxiliary process of shifting one part of the blank relative to another part, but still keeping the axis parallel
Forging: the process of heating two pieces of blanks to a high temperature and forging them into one
Finishing: the process used to refine the size and shape of the forging to fully meet the requirements of the forging drawing, such as the drum shape and truncated stick round after upsetting, the certificate of convex, concave and uneven and indented surface, and the flatness of the end surface. Bending straightening after drawing and correction after forging bevel, etc.
4. Matters needing attention
a. The size and intermediate size of the blank must meet the key points of the operation of each process, such as the heighttodiameter ratio of the material before upsetting is 22.5
b. The crosssection transformation during drawing is based on empirical data, and the change of the blank size in each process of the forging must be estimated. For example: the blank height is slightly reduced during punching, and is generally 1.1 times the height of the forging, etc.; the height will increase during the core shaft expansion, etc.
c. When making segmented indentations, it is necessary to ensure that each part of the forging has sufficient volume. For example, when the step shaft, crankshaft or gear boss is blanked, the volume distribution of each part should be done well. When forging multiple times, attention must be paid to the possibility of heating in the middle. Special attention should be paid to the deformation of the last fire and the control of the initial and final forging temperatures of the last fire to ensure the size and quality of the forging. During postfinishing, there must be enough correction margin, because in the processes of shoulder pressing, displacement, punching, etc., there are phenomena such as shrinkage on the blank, so correction margin must be left in the intermediate process
d. Forging long shaft forgings and forgings with depressions, because their length dimensions are out of tolerance and cannot be washed and upset, it must be estimated that the length dimension will be slightly extended during trimming and cause out of tolerance
e. When selecting tools, try to use general tools. When the production batch is large, special tools or fetal membranes can be made to improve the quality and output of forgings.
5. Features
a. The tools and equipment are simple, versatile and low in cost
b. It can eliminate defects such as shrinkage cavities, shrinkage, and pores in the casting pores. The above defects can be eliminated by forging and the mechanical properties of the blank can be improved.
c. The forging shape is simple and the operation is flexible. Suitable for the manufacture of heavy machinery and important parts
d. It is mainly used for singlepiece and smallbatch production, because the forging precision is low, the processing allowance is large, the labor intensity is high, and the productivity is relatively high.
6. future prospects
As a traditional metal processing technology, it has many prospects, facing both challenges and opportunities. The following are several key points for the future prospects of it:
a.. Technological innovation:
Automation and intelligence: With the development of automation technology, it will increasingly adopt robots, automated control systems and intelligent sensors to improve production efficiency and precision.
Precision forging: The development of precision its technology will make the workpiece higher in quality and smaller in tolerance, suitable for higherend market needs.
b. Market demand:
Aerospace: The demand for highperformance and highquality metal parts in the aerospace field is growing, and it has broad application prospects in this field.
Energy industry: With the development of renewable energy and traditional energy industries, the demand for large forgings will continue to grow.
c. Material development:
Highperformance alloys: With the development of new materials, i will face the challenge of processing highperformance alloys that are more difficult to deform, and it also brings new market opportunities.
d. Environmental protection:
Green manufacturing: The improvement of its technology will pay more attention to energy saving and environmental protection, reduce energy consumption and emissions, and meet the requirements of sustainable development.
e. Education and training:
Technology inheritance: With the retirement of the older generation of craftsmen, how to cultivate a new generation of its technical talents has become the key to the development of the industry.
a. Global competition:
International market: With the deepening of globalization, it companies will face competition from the global market, but also have a broader market space.
b.olicy support:
National strategy: In some countries, the government's support policy for highend manufacturing will provide support for the development of open forging technology.
Challenges include:
c.cost pressure: Fluctuations in raw material prices and rising labor costs may put pressure on the profitability of its companies.
d.Technology update: The need to continuously invest in new technologies and equipment to remain competitive is a considerable expense for companies.
e.Market fluctuations: Uncertainty in the global economy may affect the market demand for products.
Overall, the outlook for it is positive, especially driven by technological progress and market demand. However, companies need to continue to innovate and adapt to market changes to maintain their advantage in the competition.
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