The Open Die Forging Process

As its name suggests, the open die metal forging process is achieved within a relaxed environment free of
encasing devices. The metal work piece is altered through “hammer” or “stamp” movements until the
desired shape is achieved. Advanced open die forging can also produce complex shapes in addition to
simpler-shaped parts. Open die forging is often used for forging large or custom-shaped parts, including
shafts, cylinders, and discs.

Open Die Forging Advantages

Within the open die forging process, metal parts are heated at temperatures ranging from 1900°F to
2250°F and gradually shaped into the desired configuration through the skilful hammering or pressing of
the work piece. Some of the most significant benefits associated with open die forging include:

 Improved fatigue resistance

 Continuous grain flow
 Longer part life
 Increased strength
 Less chance of voids
 Finer grain size

The Closed Die Forging Process

Also referred to as impression die forging, closed die forging uses a closed, high-pressure environment to
fill an enclosed die. The forging metal is placed between multiple dies within the open die forging process
that do not entirely retain the metal. The dimensions will be changed by hammering and stamping the
metal through a series of movements until the final measurements are achieved. Closed die forging is often
used for forging smaller, high-volume parts, including connecting rods, gears, and bolts.

Closed Die Forging Advantages

Closed-die forging works with the metal’s internal grain structure and can produce more potent longer-
lasting products. The benefits associated with closed die forging include:

 Dimensions with tighter tolerances and various shapes can be achieved

 More precise, consistent impressions
 Ability to reproduce nearly any shape or size
 Better surface finish and superior mechanical properties
 Reduced or no machining
 Cost-effective for large production runs

Choosing Between Open Die and Closed Die Forging for Your Project Needs

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.

Part Complexity

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.

Volume of Production
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.

Tolerance Requirements

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.