Trenton Forging is proud to be one of the top American forging companies in the industry. We provide custom steel forging services using multi-impression progressive dies with mechanical presses, drop hammers, and more. The result is high-quality custom forgings that are designed to meet and exceed customer expectations.
What Is Metal Forging?
Every manufacturer has their own definition of metal forging. This is because there is no universal metal forging process. At its simplest level, metal forging refers to a manufacturing process where a preformed billet is pounded, squeezed, or hammered under immense pressure.
This process is superior compared to other methods, like casting. In casting, the metal is heated until it melts, but in forging, the metal is heated to a predetermined temperature before deformation. Because forging focuses on controlled deformation, this results in better, higher strength components.
Since our founding in 1967, we’ve been committed to implementing newer technologies. Our current capabilities allow us to be a one-stop shop for our customers. From custom die creation to preforming to forging, we do everything in-house to ensure better quality and precision.
Impression Die Forging
At Trenton Forging, we mainly use the impression die forging process to create asymmetrical and symmetrical forgings from steel, stainless steel, carbon steel, and steel alloys. In this process, we either use mechanical presses or drop hammers; we will determine the best equipment to use based on the type and volume of your forged components.
In this forging manufacturing process, the mechanical press quickly compresses steel between two custom dies, which results in components that have exceptional fatigue resistance and tensile strength. At Trenton Forging, our mechanical press can handle billet diameters of up to 3.5 inches and single impression size limits of 5 x 24 inches (approx. 30 pounds).
In addition to press forging, our team at Trenton may also use drop hammers. In this process, the heated billet is placed between the stationary lower die, which is connected to the anvil, and the upper die connected to the hammer ram. The ram continually drops onto the billet until it takes the shape of the profile pre-cut into the die. The upper and lower dies are custom-designed based on your specifications.
The maximum forge size for our hammers is 24 x 28 inches deep (approximately 15 to 20 pounds).
Pre- & Post-Forming
Our metal forging capabilities also include pre- and post-forming. Preforming is simply the process of transforming steel stock into a specific size and shape before it is forged. Post-forming is usually required for complex components, and ensures less waste.
Before we forge components, we use induction heaters to heat billets to a predetermined temperature. When the induction heater is turned on, it converts power to alternating electrical currents and sends them to the oscillator. Then, the oscillator sends these currents to the electromagnet, creating a magnetic field. The magnetic field transfers into the conductor, and the conductor produces eddy currents. As the eddy currents circulate, the conductor heats up. This method of heating is environmentally friendly, provides more consistent heating, and reduces overall heat loss.
3D Scanning & Reverse Engineering
We use Laser Non-Contact Surface CMMs to verify and replicate 3D surfaces of components and CREO® and Mastercam® software for part design and development.
3D Printing & Prototyping
Trenton Forging can provide 3D prototype models in just three days and custom sample forgings within two weeks. You only need to provide us with a drawing, and our team will handle the rest. We use EnvisionTEC Xtreme 3SP industrial resin printers with a tolerance limit of up to 0.004 inches in each x, y, and z axis.
If your part requires machining post-forging, we can handle it. In-house, we have six OKK vertical milling machines (9,000 to 20,000 RPM), two Haas vertical machining centers, and one Fadal vertical machining center.
Trenton Forging has an extensive in-house tool and die facility. Annually, we produce around 350 new dies and 250 resinks.
Our Standard Forging Timeline
This is how our forging manufacturing process works:
- When you come to us for your forged parts, we can create custom impression dies using blueprints and other provided specifications. We can even create conceptual digital or plastic 3D models, dies, and sample forgings in a matter of days.
- After we design your dies, we order the steel for your parts in the correct diameter and grade.
- Once we receive the steel for your parts, we cut them into billets, which are then preheated using our energy-saving induction heating units.
- We then send the heated billets into our reducer roll, which changes the shape and diameter of the billet to ensure that it can fit the profile of the custom die.
- Our team then uses mechanical presses or drop hammers to shape the forged component. Any excess material (called flash) is trimmed off and sent to a steel mill for recycling.
- After the shaping process is complete, we then put the forged component into a cooling conveyor.
- Then, we hand-inspect your components. If needed, we may also perform digital inspections or magnetic particle inspections (MPI).
Our impression die forging process allows us to manufacture high-quality components while reducing scrap waste and using less energy.
Raw Material Procurement
Product Development & Testing
Shot Blast Cleaning
Shot Blast Cleaning
Shipping & Transit
Additional Process Timing
Get High-Quality Forgings Today
For over five decades, Trenton Forging has been an industry-leading forging manufacturer in the United States. We plan to maintain our reputation by continuing to invest in innovative technology and staying committed to quality and precision. If you need forging services, don’t hesitate to call or fill out our online form to request a quote.