What are the Different Types of Shaft Forging Processes?

 Four different forging manufacturing methods are often employed to form metal components. These techniques include seamless rolling ring forging, cold forging, open die forging, and impression die forging (closed die). The shaft forging process offers a very effective approach to producing a variety of components for all purposes by applying localized compressive stresses.


Cold Forging

The cold forging technique is intended to produce parts and components with tight tolerance dimensions and an improved surface finish quality. In contrast to most other forging techniques, cold forging uses cooler temperatures to create a variety of components rather than heat to shape the part structure.
Shafts, hollow items with stems and shafts, strange combinations, and cup-shaped geometries can all be produced using cold forging.


  • Cold Forging Advantages

  • Creates tight tolerances

  • Produces good surface finish quality

  • Economical

  • Little to no material waste

  • Dies last longer than those used for heat forging

  • Increased yield and tensile strength


Impression Die Forging

The impression die forging procedure, also known as closed die forging, makes use of dies that completely enclose the base material, making it simpler to mold the material into the required shape. Impression closed die forging needs more compressive pressures than other forging techniques to guarantee that the die cavities are filled and create the whole component based on the shaft forging process.
Many different kinds of 3-D objects, weighing anything between a few ounces and many tonnes, are produced through impression die forging procedures.


  • Impression Die Forging Advantages

  • Generate less metal waste

  • Higher production rates

  • Provides enhanced fatigue and impact resistance

  • Produces parts with higher strength-to-weight ratios


Open Die Forging

Open die-produced items are formed by direct force and are also known as smith forging. The workpiece is struck by and deformed by a hammer. kept in position by two flat dies during forging with open dies. Since the workpiece is not enclosed by the dies, this method is known as open-die forging. The dies function more as tools during this forging process than they do as contained molds.
Open die forging is best for items weighing over 200,000 lbs. and measuring 80 feet in length since it can manufacture forgings weighing a few pounds up to more than 150 tonnes.


  • Open Die Forging Advantages

  • Improved fatigue resistance

  • Continuous grain flow

  • Longer part life

  • Increased strength

  • Less chance of voids

  • Finer grain size


Seamless Rolled Ring Forging

The seamless rolled ring forging procedures are suited for creating rings with diameters ranging from a few inches to 30 feet. They are typically carried out by punching a hole in a thick, circular piece of metal and then rolling and compressing the donut into a thin ring. In contrast to conventional forging techniques, rolling ring forging creates ring-shaped components using curved dies rather than flat dies.


  • Seamless Rolled Ring Forging Advantages

  • Superior structural integrity

  • Increased strength

  • Controlled directional flow

  • Eliminates welding, inclusions, and porosity


Bottom Line

If reducing downtime is essential and premature failure is not an option, get in touch with KDK Forging Co. to discuss your company's needs for forged steel shaft projects. It will be clear right away why employing forged steel shafts is preferable to using regular bar material. Our forged steel shafts are the perfect choice for machinery and components that are subject to heavy loads and pressure due to their superior strength of the press part forgings.
We make sure the forged shafts we provide are created in accordance with the unique requirements of our customers. You can visit KDK Forging Co. for more information.


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Address: K.D.K. Upset Forging Company
2645 W. 139th St.
Blue Island, IL 60406

P: (708) 388-8770




Location: 139th St, Blue Island, IL 60406, USA

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