title = "Open-Die Forging Operations"

content = """
Open-die forging (also called free forging or smith forging) is a process in which the workpiece is
deformed between flat or simply shaped dies that do not fully enclose the material. The metal is free
to flow laterally as the dies compress it, and the operator uses successive positioning moves to work
the billet progressively into the desired shape. Ridgecrest Metalworks operates open-die forging
on hydraulic presses and hammer equipment in Bay B for large-cross-section components and custom,
low-volume shapes.

Typical Open-Die Forging Operations:

Upsetting: Reduction of billet height to increase its cross-sectional area. Used to break down the
cast structure of ingots, spread material for subsequent drawing, or create flanged shapes. Excessive
upsetting without adequate forging temperatures can cause barreling and surface cracking.

Drawing Out: Elongation of the billet to reduce its cross-section and increase length. Performed by
rotating the billet and making successive die passes along its length. Used for producing shafts,
bars, and cylindrical forms.

Cogging: A heavy reduction drawing operation applied to ingots to break down the coarse cast microstructure
and refine the grain before final shaping operations. The billet is rotated and progressively reduced
along its entire length.

Punching and Piercing: Creating holes through the forging using a mandrel or punch die. Used for
producing ring blanks and hollow shaft preforms.

Saddle Forging and Ring Rolling: Large rings are forged on a saddle mandrel between the press or
hammer and an upper die, progressively reducing wall thickness while expanding the ring diameter.

Key Process Controls:

Soaking Temperature and Time: Billets must be heated uniformly throughout their cross-section to the
specified forging temperature before beginning deformation. Insufficient soak time leaves the core
cooler than the surface, leading to center cracking under compressive loading.

Reduction Ratio: The total cross-section reduction from billet to forged dimension is the key measure
of grain refinement achieved. Aerospace forgings typically require a minimum reduction ratio of 4:1
to guarantee adequate microstructure refinement.

Temperature Monitoring: Billet temperature is checked with an optical pyrometer before and during
forging. If temperature drops below the minimum forging temperature, the billet must be returned to
the furnace for reheating before continuing — forging below minimum temperature risks internal cracking.

Flash Removal: Open-die forgings may produce minor fins at die parting lines that are removed by
hot trimming or grinding.
"""

version = "0.0.1"
