Open Die Forging

This product is an Open Die forging mold, designed with a non-enclosed die structure that enables material shaping or positioning through controlled mechanical or hydraulic pressure.Unlike closed die forging, which relies on fully enclosed cavities to define final part geometry, open die forging uses open or semi-open dies to guide material flow during deformation.Open die molds are a critical component in die forging, particularly in applications that require high flexibility, large workpieces, adjustable dimensions, or progressive forming. They are widely used in open die press forging, free forging operations, and pre-forming processes before closed die forging.

This solution is ideal for manufacturers seeking cost-effective, adaptable, and durable forging molds capable of handling a wide range of materials and part sizes.

Working Principle

Open Die Forging Process

The open die forging process operates without a fully enclosed mold cavity. Instead, the workpiece is placed between two or more open dies, and pressure is applied through a press or hammer to plastically deform the material.

Process steps typically include:

1. Heating the raw material to forging temperature

2. Positioning the material between open dies

3. Applying controlled pressure through a forging press or hammer

4. Gradual shaping, elongation, flattening, or positioning of the workpiece

5. Repeating the process as needed to achieve target geometry

Because the dies do not fully encapsulate the material, the operator or automated system controls material flow during deformation.

Comparison with Closed Die Forging Process

In contrast, the closed die forging process uses matched dies that completely enclose the workpiece. Once pressure is applied, the metal fills the cavity to form a near-net-shape component.

This distinction is why closed and open die forging are often used together in advanced manufacturing workflows.

Product Features & Advantages

Non-Enclosed Die Structure

• No fully closed cavity

• Allows free or semi-controlled material flow

• Ideal for shaping large or variable-geometry components

High Process Flexibility

• Suitable for open die press forging and manual or automated operations

• Easy adjustment for different sizes and shapes

• Excellent for small batch or customized production

Lower Tooling and Maintenance Cost

• Simpler die geometry compared to closed die tooling

• Reduced machining time and tooling investment

• Easier maintenance and longer service life

Superior Load-Bearing Capability

• Designed to withstand repeated high-pressure forging cycles

• Ideal for heavy-duty die forging applications

Compatibility with Progressive Forging

• Frequently used as a pre-forming step before closed die forging

• Improves material flow and reduces stress on closed dies

Application Areas

Open die forging molds are widely used across industries where strength, durability, and dimensional flexibility are required.

Typical applications include:

• Shafts, spindles, and axles

• Rings, flanges, and bushings

• Large structural components

• Heavy machinery parts

• Energy, power generation, and marine components

• Aerospace and defense pre-forms

In many cases, components produced through open die forging are later finished using machining or transferred to closed die forging for final shaping.

Compatible Equipment

This Open Die mold is compatible with a wide range of forging equipment, including:

• Hydraulic forging presses

• Mechanical forging presses

• Open die press forging systems

• Free forging hammers

• Automated forging lines

The design can be adapted for both manual and CNC-controlled forging environments, making it suitable for modern and traditional forging workshops.

Manufacturing Process

Our Open Die forging molds are manufactured using strict quality control and advanced machining techniques:

1. Material selection (tool steel or alloy steel)

2. Precision CNC machining

3. Heat treatment for hardness and wear resistance

4. Surface finishing for improved durability

5. Dimensional inspection and load testing

The simplified structure of open dies allows faster production compared to complex closed die forging molds, while still maintaining high reliability.

Customization & Service Capabilities

We offer full customization services to support various open die forging processes:

• Custom die dimensions

• Tailored forming surfaces

• Specific material and hardness requirements

• Adaptation for specific presses or forging lines

• Prototype and small-batch support

Our engineering team can also assist in selecting the optimal combination of open die and closed die forging to maximize efficiency and product quality.

FAQ – Open Die vs Closed Die Forging

Q1: What is the main difference between open die and closed die forging?

Open die forging uses non-enclosed dies and allows free material flow, while closed die forging uses enclosed cavities to form precise shapes.

Q2: Is open die forging less accurate than closed die forging?

Yes, in terms of dimensional precision. However, open die forging offers greater flexibility and is ideal for large or custom parts.

Q3: Can open die forging be combined with closed die forging?

Absolutely. Many manufacturers use open die forging process for pre-forming and closed die forging process for final shaping.

Q4: What industries benefit most from open die forging?

Heavy machinery, energy, aerospace, marine, and custom industrial manufacturing benefit most from open die forging.

Q5: Is open die press forging suitable for large components?

Yes. Open die press forging is especially well-suited for large, heavy, or long components that cannot be easily enclosed in closed dies.