When it comes to metal forging, the two most common methods are open die forging and closed die forging. While each method offers unique advantages and manufacturing capabilities, choosing the proper method for your project depends on a range of factors, including the complexity of the forged parts, volume, and performance properties.
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At Great Lakes Forge, we specialize in open die metal forging. In this guide, we'll break down the differences between open die forging and closed die forging, including the processes, the outcomes, and the applications that tend to work best for each method.
Open die forging and closed die forging are fundamentally different in how they shape metal, the applications they serve, and the outcomes they achieve. Open and closed die forging processes are not interchangeable since they consist of different functionalities and physical parameters. Key differences between open die forging and closed die forging include:
As its name suggests, the open die metal forging process is achieved within a relaxed environment free of encasing devices. The metal workpiece is heated at temperatures ranging from °F to °F and gradually shaped into the desired configuration. It is altered through skillful "hammering" or pressing movements until the desired shape is achieved. Open die forging is often used for forging large or custom-shaped parts, including shafts, cylinders, and blocks. It is also compatible with a wide range of superior-quality materials, including 13-8 stainless steel, carbon steel, and more.
Some of the most significant benefits associated with open die forging include:
Also referred to as impression die forging, closed die forging uses a closed, high-pressure environment to fill an enclosed die. The process involves placing heated metal between two dies, creating a precise impression as the material is pressed into shape. This method is ideal for producing complex parts with consistent dimensions and is commonly used for smaller, high-volume components. Closed die forging excels in applications requiring tight tolerances, precise repeatability, and mass volumes.
The benefits associated with closed die forging include:
Multiple factors should be considered before deciding which forging method is best for your project, including the part's complexity, the production volume, and the tolerance requirements.
If the part is relatively simple, open die forging will likely be the more cost-effective method. However, if the part is complex, closed die forging may be necessary to achieve the desired shape and tolerances.
Closed die forging is generally more efficient for high-volume production runs, while open die forging is usually better suited for lower volume or custom orders. Closed die forging requires more specialized equipment and tooling than open die forging, which can affect cost and lead times.
Closed die forging typically results in tighter tolerances and a smoother surface finish than open die forging. If your part doesn't require tight tolerances, open die forging is likely the more cost-effective forging method.
If you need custom open die forgings, Great Lakes Forge is your solution. We specialize in crafting durable, high-performance parts tailored to your exact specifications. Our team combines decades of expertise in open die forging with advanced technology to deliver superior results for even the most demanding applications.
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In addition to our forging capabilities, we offer a range of secondary services to ensure your components meet the performance characteristics necessary for your application. Secondary services we offer include:
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.
Start Your QuoteThe question, “Open Die Forging or Closed Die Forging: Which is better?” can be answered simply. It depends; both processes have their advantages and disadvantages.
The question, “Open Die Forging or Closed Die Forging: Which is better?” can be answered simply. It depends; both processes have their advantages and disadvantages.
Closed-Die Forging
Closed die forgings, also known as impression-die forgings, are considered suitable for complex parts because they force metal into a predetermined shape, which can be something with intricate curves or multiple surface heights. Additionally, closed-die forgings are advantageous for parts that must be mass-produced. The closed-die forging process starts with heating metal to a malleable state, without liquefying it. The metal is then placed between two preformed dies, which resemble a mold. These dies are either pressed or hammered towards each other to guide the metal, making it flow to fill the desired shape. This process will result in a buildup of excess metal along the outer edge of the forging; this is known as flash, which must be cut away.
The actual process of closed-die forging is where you can find the disadvantages of this type of forging. Because closed-die forging forces metal into shape, there is a possibility that the metal won’t fill all of the crevasses, creating an incomplete part wasting time and resources. To anticipate the likelihood of this happening, Forging Engineers use software to predict the outcomes of the closed-die process. But, even then, because you cannot see the part being forged, there is a possibility that the forging won’t meet specifications. Next, once the forge engineers have designed dies for the part, the dies need to be created, which can a holdup the process because it takes time and money to create them. Finally, when forging with a closed-die, there is the problem of the workpiece cooling at different rates. For example, the flashing cools much faster than the inside of the part, which affects the toughness and strength of the metal, possibly compromising the integrity of the part.
Open-Die Forging
Open-die forgings, or hammer forgings, are advantageous for shapes like discs, hubs, blocks, shafts (including step shafts or with flanges), sleeves, cylinders, flats, hexes, rounds, plate and some custom shapes, which require artistic finesse or custom work. Open-die forging begins with an ingot, a piece of cast metal, which is put into a furnace until it is ductile. Once in this state, the ingot is moved to the anvil, or the press depending on the size of the operation, where the blacksmith hammers the pliable ingot into shape. Since open-die forging doesn’t require custom-created dies, it can be a faster, more cost-effective technique. To get the desired shape with open-die forging, the blacksmith moves and orients the workpiece between hammer drops to force the metal to flow a certain way. Generally, the hammer has flat dies, but on occasion, a simple-shaped die is used for specialized pieces.
The disadvantage to the process of open-die forging is that, because this process is not as precise, the forgings tend to need machining after the piece is forged. But, the disadvantages of open-die forging tend to be mitigated when using a tenured company that can specialize in near-net shaped forgings. Advanced forge shops now offer shapes that were never before thought capable of being produced by the open-die forging process.
In conclusion, every project is different from the turnaround time to requirements; and knowing what process is best suited for your project may depend on the capabilities of the forging partner you are working with. Not all forging companies are equal, so the key to getting a successful forging is finding a company who is a true partner that will work to save you time and money with capabilities that are time tested. Scot Forge has more than 126 years of experience in making custom forgings. If you think you need a forging, let our forging experts take a look and help you find a solution that is right for you, contact us today.