Closed Die forging vs. Open Die forging are metal forging processes. Find out what they are and how they differ in this blog!
People don’t always know the idea of Closed Die forging vs. Open Die forging, and that’s what we’re here for! For this blog, you’ll not only learn about the differences of the two, but we’ll also dip into their pros and cons, as well as give perfect examples of what they are!
Understanding the Forging Process
In a nutshell, metal forging is a manufacturing process where metals are shaped and formed to specific structures; these are done by applying compressive forces.
Through heat and pressure, raw metal is transformed into high-strength parts with precise shapes. In this process, metal is first heated to the needed forging temperature that makes it malleable, then placed under a hammer, press, or die to mold it into the desired form.
NOTE: Heat and pressure aren’t the only variables used in metal forging, we’ll discuss more into that below!
Types of Metal Forging
There are three types of metal forging, open die forging, closed die forging, and flashless forging. However, the first two–which are die forging–are what’s always considered the primary ones because they’re the most-used and most popular options, and they stand as the process’s fundamentals.
Let’s take a look at what each of these processes are and how they’re different from one another.
What is Open Die Forging?
Open die forging is the metalworking process that uses two dies that are open or that does not enclose the material inside.
You can think of the open die forging process as two hammers striking molten material, working to flatten or lengthen it. Otherwise known as free-forging or smith forging, it’s used to create different tool types like cylinders, discs, shafts, metal sleeves, spindles, and many more.
Furthermore, open die forging is also used to prepare for complex forging of metals; well suited for parts that have high durability and strength.
What is Closed Die Forging?
Closed die forging, on the other hand, is a precision forging process that uses two dies that are enclosed to form the shape needed. If open forging uses flat dies, this method uses dies that are shaped to match the product needed.
For instance, if you need to create specific hard and robust automotive components, you’ll need to use metal molds that would give the form of what you need.
Closed Die Forging vs. Open Die Forging: Which Metal Forging Process Fits You Best?
Some of you might still be confused as to the differences of these two. So, we created a table that would help you better understand open die forging and closed die forging.
Aspect | Closed-Die Forging | Open-Die Forging |
Process | Metal is fully enclosed within shaped dies | Metal is shaped by repeated blows without full enclosure |
Precision | High precision, ideal for detailed parts | Less precise, suited for general shapes |
Part Size | Typically used for smaller or medium-sized parts | Used for larger, bulkier parts |
Tooling Cost | Higher due to custom dies | Lower, requires fewer specialized tools |
Strength | Produces dense, high-strength parts | Offers good grain structure and strength |
Applications | Automotive, aerospace, and high-precision industries | Heavy machinery, construction, and large components |
Material Wastage | Minimal, as metal fills the die shape | Higher, as shaping requires repeated blows |
Check this video out to see both open and closed die metal forging processes in action!
What Does This Mean?
Closed-die forging uses customized dies to shape metal precisely, making it ideal for industries needing high accuracy, such as aerospace and automotive manufacturing. These components require little finishing because they are robust and dense.
On the other hand, open-die forging offers flexibility and cost-effectiveness for larger parts that are simple shapes. This process enhances the metal’s internal grain structure, resulting in parts with high durability, making it suitable for applications like heavy machinery and construction components.
As you can see, they’re different in terms of application, cost, sizing, even in material. But, when used together, businesses and organizations can manufacture exceptional components and pieces.
Similarities Between Open and Closed Die Forging
- Forging Method – Metal is shaped by extreme heat and compressive force in both open and closed die forging. For demanding applications, this shared process increases the metal’s density and durability.
- Enhanced Forging Strength – By improving the metal’s grain structure, both techniques yield robust, dependable parts with increased resilience. Forged parts are perfect for heavy-duty applications because of their increased strength.
- Utilizing High Temperatures – In order to make metals pliable for shaping, both methods depend on extraordinarily high forging temperature options. This reduces the possibility of cracking or weakening while enabling efficient reshaping.
- Flexibility in Various Sectors – Heavy machinery, the automotive industry, and the aerospace industry all use both open and closed die forging. Their adaptability demonstrates their dependability for a variety of industrial requirements.
Applications of Closed and Open Die Forging
Now that you’re more aware of their differences, let’s now discuss what they’re often used for, as well as the materials often subjected to them. Closed-die and open-die forging serve distinct applications due to their differences in certain aspects.
Open-die forging is ideal for larger parts, such as beams or shafts, and is popular in industries like construction and heavy machinery due to its ability to produce durable, high-strength components.
Closed-die forging, in contrast, is often used for small to medium parts in automotive, aerospace, and medical industries, where accuracy and complex shapes are essential.
Examples of Closed Die Forging
Some of the perfect examples of products manufactured using closed die forging are high-precision parts in automotive and aerospace industries. This include tools, gears, and structural components that need exact forming and shaping.
Think about precision parts of cars (forged aluminum rims, forged aluminum wheels, cylinders), aircraft (fuselage, fasteners, cowls), ships (aluminum hulls, forged hatch covers, engine components), and other mechanical components in certain devices.
Examples of Open Die Forging
Used for large parts in construction, mining, and heavy equipment sectors. We’re talking about beams, axles, and shafts, which benefit from enhanced strength and flexibility.
They’re more tailored towards producing high-quality components for heavy-duty and longer-lasting applications.
Why HDC is the Best in Aluminum Closed Die Forging Service
Learning closed die vs. open die forging is good, but which manufacturer and service provider should you go with?
When it comes to high-quality custom metal fabrication, we here at HDC can be your one-stop manufacturer for all requests. Mastering our craft, you’re able to choose from a base of 40 different metal types and plastics.
With more than a decade of experience, HDC can be your go-to for any process, such as CNC machining, plastic processing (3D Printing), aluminum forgings, and many more!
Don’t hesitate to give us a call if you need help! Get a free quote from us in a few hours! Work with the best, work with HDC and get world-class quality metal forging services for a cheap rate!
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