What is Open Die Forging?

A wide-range of open die forgings are offered here at Somers Forge. Open die forging is the process of shaping heated metal between a top and bottom die using force.

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The term open die gets its name from the work-piece not being enclosed. With each continuous strike of the metal, it is gradually shaped to the required dimensions increasing the strength and grain structure.

Skilled operators are essential, as they control the movements to gradually achieve the desired shape through repeated hammering.

Items are manipulated at high temperatures normally ranging from - degrees centigrade. However, it is not possible to form high precision parts from just the forging process alone; the machining of products after forging is often required to achieve the desired finish.

Our unique forging equipment is capable of forging close tolerances to minimise the amount of machining required on a finished part.

In-turn, this helps to minimise tooling costs, making open die methods more cost-effective for small production runs and one off pieces. It is particularly suitable for businesses seeking flexibility and high quality results on a smaller scale.

Closed die forging on the other hand has dies which are specifically shaped to the desired configuration, resulting in high costs to make the tool mould before adding on the forging cost itself.

The open die forge does not enclose the metal completely and therefore allows different dimensions to be created with greater properties/scope unbeatable grain structure.

What types of applications are best suited to open die forging?

Open die forging is best suited to large pieces used for short runs. These mostly consist of forged bars, blocks, shafts, cylinders, discs, hubs, flanges and custom forged shapes.

Most popular applications are often single runs or bespoke designed items. Its versatility in shaping custom and large-scale components therefore makes it the preferred choice for industries requiring flexibility and adaptability in their manufacturing processes.

Critical industries that benefit most from
open die forgings methods include:

• Defence
• Marine
• Power Generation
• Nuclear 

What is the difference from closed die forging?

Closed die forging, also known as impression die forging, is a process where heated
metal is shaped within the confines of two precision-engineered dies. Unlike open die
forging, the material is compressed and moulded into the exact dimensions of an
enclosed die impression.

Closed die forging therefore excels in crafting intricate parts
with tight tolerances. However, due to the tools and specialised machinery required,
initial costs to produce these dies are high, and so open die methods are favoured for
small runs and one off pieces.

What are the benefits of open die forging over closed die forgings?

As closed die forging uses dies which are specifically shaped to the desired
configuration, it results in high initial costs to make the tool mould, before then adding
on the forging cost itself.

Open die forging on the other hand does not enclose the metal
completely. This allows different dimensions to be created with greater
properties/scope, unbeatable grain structure, whilst also keeping costs low.

Greater Strength:

The repeated deformation during the forging process enhances the
metal’s grain structure, resulting in superior strength.

Improved Microstructure and fatigue-resistance:

The forging process improves the metal’s durability. This makes it ideal for components subjected to stress and fatigue over time, increasing the lifespan of the piece.

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Finer Grain Size:

Refined grains allow metals to deform more evenly under stress, leading to improved ductility as well as allowing for a better surface finish during
machining.

Reduced Voids and defects:

Unlike closed die forging, open die forging minimises the risk of voids, which are common in metals formed during the solidification process.

Economical for short runs:

Since there are no tooling costs involved, it is more cost-effective for producing small quantities and one off components.

By subjecting the metal to repeated pressure, the process enhances structural integrity
and grain flow, thereby reducing porosity and improving strength, durability, and fatigue resistance.

Moreover, open die methods offer quick lead times, making it economically viable for various industries without the need for bespoke tooling.

Home > Resources > The Different Types of Forging Processes 

What are the Different Types of Forging Processes?

Four types of forging manufacturing processes are commonly used to shape metal parts. These metal forging processes include impression die forging (closed die), open die forging, cold forging, and seamless rolled ring forging. Using localized compressive forces, metal forgings provide a highly effective way to create various parts for all applications.

Great Lakes Forge is a proud provider of open die forging services and other types of forging operations. Contact us today for more information about open die forging and learn what we can do for you.

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Impression Die Forging

Often referred to as closed die forging, the impression die forging process utilizes dies that completely enclose the base material, making it easier to shape the material into its desired shape. Compared to other types of forging operations, impression die forging requires greater compressive forces to ensure the die cavities are filled and form the complete part.

Impression Die Forging Advantages

• Generate less metal waste
• Higher production rates
• Provides enhanced fatigue and impact resistance
• Produces parts with higher strength-to-weight ratios

Cold Forging

The cold forging process is designed to create parts and components that display enhanced surface finish quality and tight tolerance dimensions. Unlike most other types of forging, cold forging does not utilize heat for part structure shaping but rather colder temperatures to produce various components.

Cold forging is used to create various parts and components, including shafts, hollow parts with shafts and stems, odd configurations, and cup-shaped geometries.

Cold Forging Advantages

• Creates tight tolerances
• Produces good surface finish quality
• Economical
• Little to no material waste
• Dies last longer than those used for heat forging
• Increased yield and tensile strength
• Gold
• Silver
• Copper
• Brass

Cold Forging Material Options

• Gold
• Silver
• Copper
• Brass

Custom Forged Parts

Open Die Forging

Also referred to as hammersmith forging, open die manufactured parts are shaped through direct force. A hammer strikes and deforms the workpiece, held in place by two flat dies. This process is called open die forging because the dies do not enclose the workpiece. Within this metal forging process, the dies act more like tools rather than enclosed molds.

Open die forging can produce forgings from a few pounds up to more than 150 tons and is ideal for parts weighing over 200,000 lbs. and 80 feet long.

Open Die Forging Advantages

• Improved fatigue resistance
• Continuous grain flow
• Longer part life
• Increased strength
• Less chance of voids
• Finer grain size

Open Die Forging

Seamless Rolled Ring Forging

Typically performed by punching a hole in a thick, round piece of metal and then rolling and squeezing the donut into a thin ring, seamless rolled ring forging processes are ideal for producing ring diameters ranging from a few inches to 30 feet. Compared to other types of forging, rolled ring forging utilizes curved dies instead of flat dies to form ring-shaped components.

Seamless Rolled Ring Forging Advantages

• Superior structural integrity
• Increased strength
• Controlled directional flow
• Eliminates welding, inclusions, and porosity

Get the Open-Die Forgings You Need With GL Forge

At Great Lakes Forge, we specialize in forging custom metal components and parts. Our open-die forging process produces high-strength forgings for industries that demand maximum reliability. We work closely with our customers to make sure we forge parts that meet each application’s exact requirements. With secondary services like CNC machining and heat treatment, we can produce blocks, spindles, crankshafts, and other custom-forged components that meet your specifications. From material selection to the final product, you can count on GL Forge for superior quality every step of the way.

Contact Great Lakes Forge for Expert Open Die Forging Services

Great Lakes Forge is your trusted provider of open die forging services for metal part manufacturing. Contact us for more information on our custom forging service options, or call us at 800-748-, and we’ll help you find the best custom forging solutions for your project.

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