Advantages & Disadvantages of Upset Forging
When looking for the right forging process for your next project there are substantial advantages & disadvantages of upset forging to consider. Upset Forging, otherwise known as heading, is one of the popular forging processes that we offer at our Rumbow Works site.
Upset forging allows us to have greater levels of control over the entire production cycle of your project.
What is UPset Forging?
Upset forging is achieved by setting a pre-heated metal bar into a series of grooves. This holds the metal steady in position for the pressure to compress the end of the metal into a die, also known as a tool in the forging industry.
Dies are usually used to widen the diameter of a bar of metal or increase its thickness. These tools are one of the most important aspects of upset forging, which form the metal into shape. Tools are often created using expensive, state-of-the-art technology due to the high levels of accuracy and intricacy required to produce them.
Oftentimes, you will find multiple upsetting tools within a set. Consequently, the end of the metal will gradually be remoulded into individual, radical transformations.
What are the Advantages?
One advantage of upset forging is that it can produce all sorts of long parts for a wide range of industries. These include screws, piston rods, shafts, and many more for the automotive, aeronautics, and rail industries.
Additionally, as upset forging is carried out through several stages, it can produce much more complex geometries during the deformation process. At B.B. Price, we can utilise our state-of-the-art CNC and spark erosion machines which can create bespoke tools and dies for our projects. Consequently, we do not have to rely upon third parties
Another advantage of upset forging is that it will also provide greater control over your final product. This allows us at B.B. Price to ensure that we have greater assurance over the quality of our products.
Further advantages include:
- Greater strength within the forged product designed to withstand high pressures.
- Reduced probabilities of joint fractures (compared to welded fabrications).
- No concerns about any brittleness or porosity within the forged material.
What are the Disadvantages?
As with everything, the process of upset forging does not come without its disadvantages.
One disadvantage is that it does not allow for a large variation between the original metal bar diameter and the forged head diameter. Other forging methods, such as electro-upsetting can provide a greater variation here. At B.B. Price, our upset forging process capabilities range between 10mm and 50mm diameters for any steel sections.
Another disadvantage is that brittle metals cannot be forged as they would break during the process and would not provide the necessary strength required for an upset forged product.
A third disadvantage is that, alongside any forging process, it requires highly skilled forgers, a lot of energy to run the machinery, and expensive equipment to function. These costs can often be reflected in the price of the project undergoing upset forging. At B.B. Price, however, we do our best to ensure that every customer receives a fair and highly competitive price for every project they bring to our team.