Heavy Forgings



What is open die forging?
Open die forging involves the shaping of heated metal parts between a top die attached to a ram and a bottom die attached to a hammer anvil or press bed. Metal parts are worked above their recrystallization temperatures-ranging from 1900°F to 2400°F for steel-and gradually shaped into the desired configuration through the skillful hammering or pressing of the work piece.

While impression or closed die forging confines the metal in dies, open die forging is distinguished by the fact that the metal is never completely confined or restrained in the dies. Most open die forgings are produced on flat dies. However, round swaging dies, V-dies, mandrels, pins and loose tools are also used depending on the desired part configuration and its size.

Although the open die forging process is often associated with larger, simpler-shaped parts such as bars, blanks, rings, hollows or spindles, in fact it can be considered the ultimate option in "custom-designed" metal components. High-strength, long-life parts optimized in terms of both mechanical properties and structural integrity are today produced in sizes that range from a few pounds to hundreds of tons in weight. In addition, advanced forge shops now offer shapes that were never before thought capable of being produced by the open die forging process.

The Open Die Forging Process

Steps to produce a typical spindle-shaped part:

  1. 1 Rough forging a heated billet between flat dies to the maximum diameter dimension.
  2. A "fuller" tool marks the starting "step" locations on the fully rounded workpiece.
  3. Forging or "drawing" down the first step to size.
  4. The second step is drawn down to size. Note how the part elongates with each process step as the material is being displaced.
  5. "Planishing" the rough forging for a smoother surface finish and to keep stock allowance to a minimum.
Grain Flow Comparison

Forged Bar:

Directional alignment through the forging process has been deliberately oriented in a direction requiring maximum strength. This also yields ductility and resistance to impact and fatigue.

Forged Bar

Machined Bar:

Unidirectional grain flow has been cut when changing contour, exposing grain ends. This renders the material more liable to fatigue and more sensitive to stress corrosion cracking.

Machined Bar

Cast Bar:

No grain flow or directional strength is achieved through the casting process.

Cast Bar

Products supplied & Industries catered

We are using 1600 tons & 3100 Tons oil Hydraulic presses with rail bound manipulators & state of the art Heat treatment & Machining facilites to produce quality forgings for various Insustries & applications. Our strength is the strict quality controll at every stage and the prompt deliveries.

Forgings are supplied to the following industries and in following material grades:

  • Carbon Steel
  • Alloy Steel
  • Stainless Steel
  • Die Steel
  • Hot & Cold Working Tool Steel


Mill Roller Shafts : up to 45 x 90
Pinion ( EN 24 ) & Pinion Shafts
Tail Bars
Shredder Shafts
Cane Cutter Shafts
Fibrizor Shafts


Blooming Mill Rolls
Universal Couplings
Roll blanks for Cold Rolling Mills
Hardened Hot Rolling Mill Rolls for slab, plate mills, etc.


Gear Blanks / Rims
Excavator Axles
Excavator / Shovel Components
Wheel and Gear Shafts


Integral Flange Shaft
Pump Casing
Stainless Steel Pump Shafts
Fluid Ends


P-20 Blocks for Plastic Injection Moulding
H-13 Tool Steel Blocks for Pressure Casting Tools


Die Blocks (DIN 2714 grade)
Crankshafts for upsetters


Wind Mill Shaft


Pinion & Pinion Shafts
Kiln Support Rollers
Tie Rods
Crusher Shafts

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Email: info@alliedautomation.in