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In impression die forging, a workpiece is plastically deformed between two dies filling the die cavity. A small amount of material or "flash" that flows outside the die impression cools rapidly, creating resistance that facilitates material flow into unfilled impressions.
Horizontal forging machines (upsetters) produce impression die forgings similar to those made on hammers or presses. "Grip dies" (the fixed die and moving die) correspond to the bottom die on a hammer or press; the ram-operated header die corresponds to the top die.
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Forging Terms and Definitions
From Alloy steel forging to Cold heading
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Like other technical fields and engineering disciplines, forging technology has a language all its own. Knowing what these terms mean and how they are applied can be of enormous help in seeking quotations, specifying forged products over other alternatives, and understanding why forged components deliver superior performance over non-forged parts.
Aluminum precision forging plastically deforms an aluminum alloy to a finished part shape in special dies. By design, little or no subsequent machining/processing is required as a result of close tolerances, thin sections, small radii and minimum draft angles.
Alloy steel forging: one made from a steel containing additional alloying elements other than carbon (e.g.. Ni, Cr, Mo) to enhance physical and mechanical properties and/or heat-treat response.
Bar: a section hot rolled from a billet to a round, square, rectangular, hexagonal or other shape with a cross-section less than 16 sq. in.
Billet: a semifinished section (width <2X thickness), hot rolled from a metal ingot, generally having a cross-section ranging from 16 to 64 sq. in. Also applies to a hot-worked forged, rolled or extruded round or square.
Blank: raw material or forging stock from which a forging is made.
Bloom: same as a billet, but with a cross-sectional area greater than 36 sq. in.
Blocker-type forging: one with the general shape of the final configuration, but featuring a generous finish allowance, large radii, etc.
Carbon steel forging: one made from a steel whose major alloying element, carbon, produces the resultant properties and hardness.
Close-tolerance forging: one held to closer-than-conventional dimensional tolerances.
Closed die forging: see impression die forging.
Coining: a post-forging process - on hot or cold parts - to attain closer tolerances or improved surfaces.
Cold-coined forging: one that is restruck cold to improve selected tolerances or reduce a specific section thickness.
Cold forging: various forging processes conducted at or near ambient temperatures to produce metal components to close tolerances and net shape. These include bending, cold drawing, cold heading, coining extrusion (forward or backward), punching, thread rolling and others.
Cold heading: plastically deforming metal at ambient temperatures to increase the cross-sectional area of the stock (either solid bar or tubing) at one or more points along the longitudinal axis.
Courtesy of Forging Industry Association
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