All the copper, brass & bronze forgings produced in CFS Forge are in closed die forging process operated under hot or room temperature, in which dies (also called tooling) that contain a precut profile of the desired part move towards each other and covers the heated copper bar in whole or in part.
The heated raw material, which is approximately the shape or size of the final forged part, is placed in the bottom die. The shape of the forging is incorporated in the top or bottom die as a negative image. Coming from above, the impact of the top die on the raw material forms it into the required forged form. Then, the copper forging blanks will be placed in punch machine to remove the flash, this process is called trimming. Finally, put these copper forging blanks into shot blasting machine to remove surface mill scale and dirt oil, so that the surface is smooth and clean. Copper forgings from 0.01kg to 20kg can be made using this process.
Hot forging or cold forging of copper alloys can produce an almost limitless variety of 3-D shapes that range in weight from mere ounces. Hot copper forgings are routinely produced on hydraulic presses or mechanical presses and punch machines, with capacities up to 1,250tons.
During copper forging process, two or more dies containing impressions of the part shape are brought together so that copper forging billet undergoes plastic deformation under high pressure and high or room temperature. When the upper and lower dies touch each other, metal flow is restricted by the die contours, so our copper forging process can make copper forgings with complex shapes and closer tolerances, no matter the final shape is symmetrical or non- symmetrical shapes. Copper forgings with symmetrical shapes are like coupling, finger, handle, tee, ect. Besides, there are also some non-symmetrical shaped copper forgings, such as valve fittings, taps and other customs copper components. The whole copper forging process seems complex, but very quick, and can be suitable for both small and large production runs.
In terms of alloys used in copper forging process, they can be classified in red copper alloys, brass alloys and bronze alloys. Red copper alloys are C11000, C12000, C10100, C10200, ect. Due to the high copper content, this type of copper forgings are the most expensive. Brass forging alloys include: C37700, C36000, C37100,ect. For its less copper content than red copper, brass forgings are the most widely used in industrial applications. The last type of copper forging alloy is Bronze alloy, include C83600, C95400, ect.
The last process capability is the tolerance controlled in copper forging process. The general forging tolerance is normally at a range of ±0.25mm~±0.5mm, which is mainly decided by the weight & dimensions. Besides, the precison of forging dies will also affect the tolerance of copper forgings. The more precise the forging dies, the smaller the tolearance will be.