Flanged-End Forgings Flanged-End Forgings Scot Forge can provide custom flanged-end forgings with heads that are upset in a variety of shapes, including single, tapered, or multiple diameters. Using custom-made or in-house tooling, we can upset: Bars from 3.75x" to 12" starting diameters in 15' to 50' lengths Finished head diameters 5" to 15" (up to 24" with open upset) Starting Stock Options Starting stock can be an in-house Scot Forge forged bar, from 6" to 12" diameter, or we can convert your 3 ¾" to 12" outsourced bar stock. Scot Forge maintains an extensive inventory of material, including carbon, alloy, and stainless. Material Savings with Near Net Shape Our upset forging process produces parts close to net shape with forged-in instead of machined-in steps, tapers, and I.D./O.D. dimensions. This avoids excessive material usage, unnecessary machining, and their related costs. Impact Strength Proper orientation of grain flow assures maximum impact strength—resulting in superior quality over machining from bar stock. Repeatable Quality With an automated integral control system, along with precise production and quality control parameters, our upset press can yield flange ends with accurate and consistent quality. Flexible Quantities and Fast Delivery Our upset press handles high or low volume flanged-end parts. Once tooling is produced and bar stock is available, processing can begin immediately, and you can order smaller release quantities based on need. Your flanged-end parts may be available in just a few weeks if no further processing is required. Upset Press Process Designed and built by Scot Forge engineers, the 2,000 ton press can upset most simple or complex shapes in a single pass. The typical upset process steps are: the automated system delivers the bar to the induction heating element the appropriate end is then heated to forging temperature the bar is then moved to the press and a single pass upset produces the desired flanged-end shape finally the bar is transferred to the automated cooling bed Forge simulation software is used to create the forging sequence. This data is used to determine the correct starting bar size and tool design based on the upset press capabilities. Material Savings Forging can measurably reduce material costs when compared to machined bar, since it requires less starting metal. When machining a solid bar to form a shaft with a step or tapered head, there is some waste of material, labor, and time. All excess material, as shown here, is turned into scrap. The material loss, machining, wear and tear on the machine tools, and high freight costs due to the excess weight inflates your costs. With an upset forging, the part is shaped to size with minimal waste. Upset forging the bar to form a shaft with a step or tapered head requires less starting material, thus saving costs on excess material. Forging typically results in less secondary machining, which saves money and time while producing a near net shape. Additionally, freight and handling costs are lowered because the forged upset shaft weighs less than the bar. Grain Flow Comparison Upset 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. Comparative Analysis When Compared To... Upset Forged Metal Parts Deliver... Machined Bar Contoured grain flow yielding greater impact and directional strength Cost savings in material and reduction of waste Less machining and longer tool life Broader material options and size ranges Weldments/Fabrications Superior and more consistent metallurgical properties Reduced labor, rejection, and rework/replacement costs Stronger parts due to the elimination of welds Single-piece design and inspection efficiencies Simplified production requirements A copy of Flanged-End Forging Solutions from Scot Forge is available in pdf format. To view pdfs, you will need Acrobat Reader. Download a free copy if needed.