Drop hammer forging is a metal fabrication method that uses two die halves, each with opposing female impressions (much like molds), one on a stationary anvil and the other attached to a moving ram.
The method is called ‘drop hammer forging’ because drop hammers are the primary pieces of equipment used throughout the process. In drop hammer forging, a pre-heated metal billet (workpiece) is placed onto the lower half of the die-set.
The ram, with the upper half of the die-set attached, drops onto the lower die held by the anvil (hammer base), delivering a set number of blows to deform (shape) the hot metal, filling the female impressions in both dies. The number of blows needed will vary depending on the item that is being manufactured. The impressions fill, leaving excess material (flash) which is trimmed away and recycled, leaving behind the finished forged component.
Advantages of Drop Hammer Forging
Compared to other fabrication processes, drop forging offers a number of benefits. This process allows you to optimize the grain flow of the raw material relative to the component’s function or end-use to reduce the risk of failure at common stress locations. The components Trenton Forging makes using this process are generally stronger and work for longer in high-stress conditions.
Other benefits include:
- No wasted material. Any excess material is recycled.
- Fast production method
Common Drop-Forged Components
Drop hammer forging is an efficient way to produce specialty components and tools, including:
- Wrenches
- Connecting rods
- Crankshafts
- Levers
- Gears
Is Drop Forging Expensive?
Typically, drop forging is not as expensive as customers assume. First, it can produce parts at a low marginal cost after the initial tooling investment. It also helps save on raw material usage due to high efficiency. In many circumstances, this can be a cost-effective option for the following reasons:
- Drop forging produces products with excellent structural integrity.
- The tooling for drop forging lasts for relatively long service lives, making the process even more cost-effective.
- Drop forging has rapid cycle times, allowing for greater productivity.
- There are many design opportunities available with closed-die drop forging that are not possible with some other types of metal forming.
- A wide variety of metals can be forged including steel, stainless steel, alloys and more.
Considerations With This Production Method
While the drop hammer process offers many advantages, it is ultimately an advanced manufacturing process. The dies, or tooling, needed for the process must be created by a skilled team to ensure accuracy. Metallurgists and engineers may be required to determine which metal is best suited for the application, the temperature to which the metal must be heated, and how many blows are needed to fill the final impression. Lastly, the drop hammer forging method may not be the best method for your specific application. A forging expert can help you decide which forging method will be the most cost-effective and efficient for your unique application.
Learn More From a Trusted Forging Manufacturer
If you have questions about drop hammer forging, or need help creating specialized components, don’t hesitate to contact our team at Trenton Forging. From conception to shaping to finishing, we work with you every step of the way to produce accurate, durable, and strong parts.
