upset forging process exampleUpset Forging is just one of many forging processes available from Brooks Forgings Ltd.

Our forge located in Stourbridge UK produces upset forged components on a daily basis. Please contact us today with your requirements.

Typical examples of upset forged components are Eye Bolts, Holding Down Bolts and Torsion Bars.

16 Hot Forging Cells Now Online

Click Here to email us about Upset Forging

upset forging process

Our Upset Forging Capabilities

upset forging process exampleOur capabilities include both vertical closed die and horizontal split die upset forging machines.

Capacity from 6mm – 100mm diameter bar stock up to 10 meter lengths, including flat, square and hexagonal material.

We also have the diversity to manufacture forgings from a wide range of materials.

Ranging from carbon steels through to exotic alloys… we can help you with your forging requirements.

image upset forging

We specialise in the Upset Forging of round bar from 6mm up to 100mm diameter. This process is best suited for the production of usages or close net forgings, commonly used by machinists who are proactive in reducing costs, saving material and offering a more reliable component. The above image is a perfect example showing the amount of material that can be saved for a component requiring a reduction in diameter.

The Benefits of Hot Upset Forging

• Inherent strength retained by containing metal grain flow.
• No stress areas created where material size needs to be reduced.
• No brittleness or porosity concerns (sometimes prevalent in the casting process).
• No concern of fractures at weld joints (as could occur on fabrications).

upset forging process

The Upset Forging Process

Upset Forging is accomplished by holding pre-heated material between grooved dies, commonly known as ‘grip dies’. Pressure is then applied to the end of the bar in the direction of its axis.

The Heading Tool upsets the end of the bar by displacing the heated metal within a cavity. It’s not uncommon to have several upsetting operations on one die set, gradually forming the bar to its required shape.

Grain Flow Comparison

forged bar grain flow

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.

machined bar grain flow

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.

cast bar grain flow

Cast Bar:

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

automated horizontal upset forging

Automated Horizontal Upset Forging

At our manufacturing facility in Lye, West Midlands, we have installed several Horizontal forging lines capable of producing upset forgings.

The walking beam transfer unit makes the use of several compressed air cylinders to transfer the work piece from one die to the next and is easily capable of increasing output by up to 3 times that of conventional manual operation.

upset forging forged head style examples for special bolts

The majority of bolting and fastener components used in the industry today are manufactured using the Upset Forging process. There are two types of processes, horizontal split die upset forging and vertical closed die upset forging. The image above shows some of the head styles that can be achieved. Variations of these styles are also common, supplied as forged usages to many machinists and engineers worldwide.

Request a Quotation

  • Tel: +44 (0)1384 563356
  • Fax: +44 (0)1384 563357


Horizontal Multiforge - Upset Forging

The Multiforge is a unique concept with distinct advantage over conventional hot upsetting forging machines.

One of its main features is the departure from conventional vertical opposed gripping dies and the innovation of the horizontal disposition.

Not only is the weight eliminated but in addition the operator is working at a constant height. Without the need to raise and lower the component between die impressions, as the case on conventional vertical grip die machines.

The generous die width enables five forging stations to be set up in one tool assembly which can often eliminate secondary processing of certain components which require multiple operations.

Click here to view our video library...Click here to view our video library...
Click here to view our image galleries...Click here to view our image galeries...
Click here to view our download library...Click here to view our download library...

Request a Quotation

  • Tel: +44 (0)1384 563356
  • Fax: +44 (0)1384 563357
All content and imagery found on this site is subject to Copyright © Brooks Forgings Limited 2021 and may not be reproduced or distributed without their express permission.
Site by Charles Design