Forged Cutting Tool Attachments
You often see forged cutting tool attachments being used in the mining and forestry industries. The reason why is because forging produces tools and components with the exceptional strength and reliability necessary for extremely demanding occupations.
Industrial forging refines the grain flow and imparts uniformity. The result is parts with superior mechanical properties, such as strength, ductility, fatigue, and impact resistance.
The Forging Process
The closed die forging process involves shaping various heated metals through compressive force. An ingot or billet is heated to the level of plasticity then formed between dies. Pre working may also occur to remove porosity and refine the dendritic structure of the forging stock.
The refined grain structure of forged components results in superior directional strength, tensile strength, and impact toughness. Because the porosity and internal voids are removed, the metal has a predictable, uniform response to the heat treatment. The resulting structural integrity is highly desired for reliable performance under field-load conditions. An American forging company such as Trenton forging can produce parts in conformance with almost any impact, load, or stress requirement.
Forging services provide parts with exceptional wear resistance required for rigorous applications like mining and forestry cutting tools. It has a long-term cost advantage over steel casting due to the improved strength, durability, and quality. Trenton Forging is an industry-leading forging company known for forging cutting tool attachments and forged mining tools.
Common Types of Forged Forestry Cutting Tool Attachments
Loggers and foresters depend on a variety of durable, dependable forestry cutting tools and other heavy-duty equipment for processing trees. Forging cutting tool attachments imparts the strength and reliability required to ensure the workers’ safety while processing timber. Forged components for the forestry industry may include auger bits, chipper bits, drills, grinder tips, pick blocks, chisel bits, and fire rakes.
Forging cutting tool attachments are designed to be used with a variety of heavy forestry equipment, such as:
- Feller bunchers
- Log loaders
- Stump grinders
Forged Mining Tools
Mining relies on equipment that can withstand the rigors of subsurface digging, crushing, and load conveyance used in the industry. Heavy equipment like crushers, draglines, drills, excavators, mining trucks, shovels, and wheel loaders help navigate the severe conditions and extreme circumstances of these challenging applications. Metal and mineral extraction depends on drills that can create various openings from small holes for explosives to larger ones to allow passage for miners and crushers to reduce the rock to more manageable proportions. Earthmovers transport the underground debris to make way for deeper access.
Mining forgings can be sturdy main shafts, end plates, grinder tips, and flight bars. Other common forged mining parts include:
- Bits and consumable teeth for augers, chippers, and chisels
- Dragline and rope shovel components
- Frames, spindles, and side straps
- Inserts for hammerheads
- Pick blocks
- Raker forgings
- Seamless bull gears, center hubs, doughnuts, gear blanks, rims, rolled rings, sleeves, and pancake forgings
- Tooth inserts and holders
Closed Die Forging Process
The closed die forging is a staged process used for forging cutting tool attachments and forming strong, durable mining parts and components. Also called impression die forging, closed die forging uses two dies. The bottom die holds the heated forging material. The top die covers the bottom die as they move toward each other.
The first stage of the process forms the rough shape or edging impression. Subsequent blocking cavities introduce additional details like bends and fillets. The final stage is the impression cavity. This die ensures the part meets the required specs.
In the closed die forging process, the metal takes the shape of the die through impact. The die is attached to an anvil, and a hammer forces the metal into the contours of the die through a rapid concussion. The excess material or flash is forced from the die and cools quickly. After forging, the flash is removed.
The overall process starts with the procurement of the raw materials. Product development and testing must occur before the part can be forged, then proceeds to shot blast cleaning, heat treating, and coining and piercing before the final inspection and shipping. Post-forging processes can provide additional requirements, depending upon application needs. They can include coating, Blanchard grinding, machining, non-destructive testing, pull testing, and roll marking.
At Trenton Forging, we use closed impression dies and air-lift gravity drop hammers to ensure our Forging Cutting Tool Attachments and mining parts have the optimal mechanical properties necessary for demanding jobs. By forming the steel, stainless, and steel alloy billets in closed dies, we ensure a superior grain structure that results in exceptional strength, reliability, and structural integrity.
The scope of our closed die forging operation accommodates the following specifications:
- .01 – 15 pounds
- Cross-sections of 2.875” and smaller
- Draft angles of 7 degrees or greater
- Maximum length of 24”
- Radii 0.060” and larger
- Steel, stainless steel, and steel alloys
Many forging processes require extensive post-processing. However, our closed die forging process forms a near-net-shape that retains the original grain structure of the raw material and improves upon it. That results in little to no required post-processing. When compared to other forming processes like fabrication, casting, or machining, the parts are stronger, longer-lasting, and often lighter and more efficient.
This highly precise subtractive manufacturing process produces parts as small as one-tenth of a pound with the same strength, ductility, fatigue, and impact resistance as those much larger. Using custom machined dies and drop hammer forging, the metal takes on the geometries of the specially designed dies. The pre or post-working processes ensure the metal parts have unrivaled functionality and durability.
Forging vs. Casting
Though both forging and casting are used to form tools and equipment for various industries, forged parts are preferred for forestry and mining equipment due to their exceptional reliability, strength, and other beneficial mechanical properties that ensure safety and part longevity. Forged parts outperform cast parts with:
- 26% higher tensile strength – Tensile strength provides additional stability under stress.
- 37% higher fatigue strength – The higher the fatigue strength, the longer the part lifespan.
- 44% more yield strength – Yield strength indicates the ability to withstand higher loads before deforming.
- 58% area reduction when pulled to failure – This measures the amount of deformation a part can accommodate without failure.
The improved mechanical properties of forged products are due to the uniform grain structure introduced during forging. The grain size of metal expands and becomes random when melted, weakening the metal and making it unsuitable and unstable for heavy-duty equipment. Forging tightens the grain structure. The result is a mechanically stronger product created without the expense of additional alloys.
American Forging Company
Trenton Forging is a leading American forging company dedicated to the core values of trust, integrity, innovation, and urgency. Our process leverages the best in experience, knowledge, and technology to produce reliable parts for the nation’s most demanding industries.
Since 1967, we have never wavered from our commitment to adapt, change, and respond to our customers’ needs, including meeting the tightest timelines. Our customers depend upon the fast turnaround times we are known for while recognizing that we never sacrifice quality or conformance to their requirements.