Upset Forging

The UK's leading specialist with 16 Upset forging cells online producing components up to 100mm diameter and 6-meter length in specialist materials on request.

Brooks Forgings specialise in the production of upset forged components from 6mm up to 100mm in diameter and 6-meter length. Continuous investment has increased production capacity to 16 upset forging lines featuring both horizontal and vertical machines.

Upset forging is used in conjunction with other processes to produce many types of components such as Eye Bolts, Shackles, Holding Down Bolts, and Torsion Bars. Any component that requires the alignment of grain flow, starting from a diameter bar, into a head or shape on the end of a bar will be formed using the upset forging process.

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The Benefits of Hot Upset Forging

• Inherent strength retained by containing metal grain flow.
The raw material used in the forging process contains a directional grain flow. Through closed-die forging techniques, the material is compressed to the desired shape. Grain flow follows the shape and contours of the component which enhances strength and resilience.

• No stress areas created where material size needs to be reduced.
If a reduction in size occurs in the forging process, the material grain flow is compressed and aligned. For example, if the raw material is machined the grain flow is cut and potentially creates areas more liable to fatigue and stress cracking.

• No brittleness or porosity concerns that are sometimes prevalent in the casting process.
When metal is reduced to molten form it loses all of its grain flow structure. Depending on the casting process and material type used the component can become brittle or porous causing failure during application.

• No concern of fractures at weld joints as could occur on fabrications.
Fabricated components are often made up of several pieces that fail at the weakest point, the weld.  It can be beneficial to produce these components as a one-piece forging, removing all welds and offering a stronger more resilient solution.

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Reduce your machining times and raw material wastage.
Gain the benefits of aligned grain flow

We specialise in the Upset Forging of round bar from 6mm up to 100mm in 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.

Our illustration is a perfect example showing the amount of material that can be saved for a component requiring a reduction in diameter.

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Aligned Grain Flow Explained

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

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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.

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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 use of several compressed air cylinders to transfer the workpiece from one die to the next and is easily capable of increasing output by up to 3 times that of conventional manual operation.

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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.