When you’re looking for a reliable metal producer to fulfill your manufacturing requirements, Deeco Metals is the company to contact. We understand metals and metal processes. With fundamental qualities like technical expertise, honest communication, good service, quality, and experience, we work to provide our customers with the best custom metal producing experience in the industry. We use the most modern and effective manufacturing methods available to produce custom made brass and bronze extrusions, all metal castings, metal stampings and metal forgings, made of ferrous and non-ferrous alloys.
Our closed-die forging method produces both quality and cost effective parts for many diverse industries. The manufacturing process can be broken down into the following four basic operations:
1. A metal billet is heated to a “plasticity” condition. Once this is done and prior to placing this billet on the bottom die, a special graphite or lubricant is applied to the bottom and top die sections. This is used for various reasons. Primarily, this compound keeps the forged part from sticking to any of the die sections and also reduces friction and wear of the die.
The bottom die resembling half of the desired shape of the part is attached to the bottom die plate holder in the forging press. The other half of the die, representing the top part and other half of the forged part, is attached to the top die plate holder of the forging press.
2. Once the hot billet is placed in the bottom die, the press is activated and the top half of the die strokes downward at considerable force. This force is sufficient to allow the top die to meet the lower die and form the hot metal billet into the desired forged part. This downward stroke is quick and the two dies are likely to only come into contact with each other for a short period of time.
3. A one stroke operation is often sufficient on smaller parts and when using certain metals, like brass and aluminum. However when forging steel or larger parts, multiple strokes may be required. This is determined by the metal being used or the size and complexity of the part and whether or not there is coring in the dies.
4. During the forging operation, excess metal squeezes out along the line where the two dies meet. This excess is called “Flash” and is removed, once the part has cooled, by placing the part into clipping die attached to a clipping press. Once trimmed, the part can be further processed, by heat treating, shot blasting, vibratory finish, pickling (acid bath for removal of surface scale) and/or machining.
While the initial cost of dies may be relatively high, the piece price can be very cost-effective. The design of the die, especially when coring is done, results in a product that is not only competitively priced, but also tough and durable. The process has low recurring costs and is most beneficial for long runs often associated with automotive and tool products. Small runs are also offered, however as mentioned above, this process becomes more economical with increased volume. The forging process produces parts with a high strength-to-weight ratio compared to cast or machined parts and when comparing the other manufacturing processes, forged products are subject to less chance of flaws resulting in fewer rejects.
Whether you’re in need of custom closed-die forging or other metal casting services, Deeco Metals can be your one stop shop for your metal products. Our quick turnaround times and JIT or Kanban inventory services are the best in the industry. Visit our website to see how easy it can be to work with Deeco for your custom made metal product requirements.