Project in mind?
Please call us now on
+44 (0)1384 563356
Email your enquiry to
sales@brooksforgings.co.uk
Closed die upset forging and drop forging are used in our near net shape manufacturing process.
The term 'near net shape' refers to a blank or usage that is forged to be close to the size and shape needed for the final component. This process aims to minimise raw material waste and reduce subsequent machining, resulting in significant cost savings and faster production times.
Forged near-net shapes also benefit from aligned and compressed grain flow, which gives finished machined parts greater strength and resilience compared to fully machined or cast components. We offer upset forging, drop forging, and open die forging processes, which allow for the production of blanks in a wide variety of shapes and sizes.
Machinists - Why Move to Near-Net Forgings?
Moving from full-billet process to a near-net-shape forging isn't just about saving material; it's about optimising your entire shop floor.
• Slash Cycle Times: Skip the heavy roughing passes and get straight to the finish work.
• Drastic Waste Reduction: Stop paying for high-grade alloy just to turn 60% of it into scrap.
• Superior Part Integrity: Benefit from the continuous grain flow that only forging provides - billet machining can't match that strength.
• Tooling Longevity: Save your expensive inserts and end mills by removing less bulk material.
The Bottom Line: If your bins are full of swarf and your machines are running 24/7 just to "find" the part inside the billet, you're leaving margin on the table.
The Engineering Advantage
Beyond the clock and the wallet, there is a structural argument to be made. In a billet, the grain flow is unidirectional. When you machine complex geometries into it, you "cut" those grains, creating potential stress risers.
In a near-net forging, the grain flow is forced to follow the geometry of the part. This results in a component with higher fatigue resistance and greater impact strength, even at a lighter weight.
Calculating Your "Material Utilisation" Ratio
A simple way to see if this move is right for you is to look at your material utilisation ratio: the weight of the raw material purchased versus the weight of the finished part. If you are buying 20kg of material to produce a 5kg part, in large quantities, your process is a prime candidate for forging.
