Where quantities are large and the design is simple, considerable savings result from the use of multiple cavity dies, with more than one part being produced at a time. Forging rates vary between 100 and 1,200 pieces per hour with the majority of forgings being forged at 200 to 600 piece rates. This permits the use of single cavity dies rather than the more expensive progressive dies required by hard-to-forge materials, and reduces labor costs, die costs, and heating costs.
Since copper and copper alloys are readily forged, most commercial forgings are produced with a single closing of the press, no re-strike or reheating being required. With a downward stroke of the forging ram, the upper die is forced against the slug to form the part. The dies are heated to insure proper metal flow, and the heated slug is placed in the lower half of the die cavity. To insure a quality part, the forger must carefully control the slug temperature, as too cold a slug will not fill the die cavity completely whereas too hot a slug will result in a porous surface. The slugs are then heated to forging temperature. There the rod is cut into slugs of precise length to insure filling the die cavity during forging. Back to Top The Hot Press Forging Process Rod CuttingĪt the brass mill, billets cut from a cast ingot are hot extruded into rod which is further processed before delivery to the forge shop. These problems include leak integrity, close tolerances, high strength with low weight, and non-symmetrical shape. However, smaller quantities of copper alloy forgings can also prove economical when specific design problems must be solved. Mass production of forged parts lends itself to maximum savings. The precise designs on the die surface can produce sharp impressions on the forging surface, which is not economical with other forming processes. Dimensions show minimum variation from part to part and permit automatic chucking and handling in subsequent operations.
Overall part dimensions are held closer than in sand casting. Close TolerancesĪ forging produced in a steel die with close tolerances offers several advantages. Often the thinner forged parts result in lighter weight and lower piece cost compared to other forming processes. The dense non-porous forged metal permits the designer to specify thinner sections without the risk of leaks due to flaws and voids. The tensile strength of the parts is thereby increased, and resistance to impact and abrasion is enhanced.
The double working under pressure compacts the metal and produces a very dense and refined grain or fiber structure. In making a forging, the metal is worked twice under tremendous pressures-first during rod extrusion and then during forging.
#FORGING DIE DESIGN HANDBOOK PLUS#
These advantages result from the inherent properties of copper and copper alloys plus additional improvements in mechanical and physical properties imparted by the forging process. Attractive solid colors-not just surfaceīack to Top Advantages of Copper and Brass Forgingsįorgings of copper and brass offer a number of outstanding advantages over parts produced by other manufacturing processes.Superior polishing and finishing characteristics.Excellent joining and plating characteristics.High electrical and thermal conductivity.Alloys can be selected to utilize the following unique characteristics: Unique Combinations of PropertiesĬopper, brass and bronze forgings offer the designer unique combinations of properties that other metals cannot match. An extensive glossary of terms used in the industry and information required for ordering are included to improve communication between user and supplier. A a tabular guide to the tolerances commonly specified for forgings of different types is included. It reviews competitive processes, comparing their advantages and disadvantages with forging.
This material will help design engineers and purchasing departments maximize the utility and cost advantages inherent in the specification of brass and copper forgings. Excellent surface finish with a clean lustrous appearance is readily available with copper and brass forgings. Forming under heat and pressure in precise closed dies produces dimensional accuracy-always repeatable, part to part and lot to lot. As a result of hot working, forged materials have superior density and freedom from flaws. Advantages of Copper and Brass ForgingsĬopper and brass forgings are quality parts, comparing favorably in material integrity, dimensional tolerance and surface finish with products made using other major metalworking processes.