At our forging workshop with over 25 years of expertise, free forging remains one of the most fundamental and flexible metal forming techniques. Among our forging equipment, the 5 Ton Hydraulic Hammer plays a critical role in producing custom-shaped parts with high structural integrity. In this article, we’ll walk you through how free forging is performed using a 5 Ton Hydraulic Hammer, and what advantages it brings to industrial applications.
What Is Free Forging?
Free forging, also known as open die forging, involves the deformation of metal between flat or simple contoured dies. Unlike closed die forging, the dies do not completely enclose the workpiece, allowing greater flexibility for customized shapes and small-batch production.
Steps to Make Free Forging with a 5 Ton Hydraulic Hammer
1. Material Preparation
The forging process begins with cutting raw material (usually carbon steel, alloy steel, stainless steel, or other forgeable metals) to the required size. The billets or ingots are then preheated in a forging furnace to reach the optimal forging temperature — typically between 1100°C and 1250°C.
2. Positioning the Workpiece
The heated billet is transferred to the anvil of the 5 Ton hydraulic hammer using tongs or a manipulator. It must be quickly positioned to avoid excessive heat loss.
3. Initial Shaping (Upsetting & Drawing Out)
The operator performs upsetting to increase cross-section or drawing out to increase length. This is done by repeated controlled strikes from the hydraulic hammer, which delivers a powerful vertical force with great precision.
4. Edging, Bending, and Punching
Depending on the final shape, the workpiece undergoes edging to gather material, bending for curved forms, or punching to create holes — all done manually or with simple tools under the hammer.
5. Reheating & Final Shaping
For complex parts, multiple reheatings may be required. Final shaping ensures dimensional accuracy and grain flow alignment for enhanced mechanical properties.
6. Air Cooling or Controlled Cooling
Once the forging is complete, parts are cooled naturally or in a controlled environment to relieve internal stress.
7. Surface Treatment & Inspection
After forging, the part may be shot-blasted, rough machined, and undergo NDT inspection (ultrasonic or magnetic particle testing) to ensure internal soundness.
Advantages of Free Forging with a 5 Ton Hydraulic Hammer
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Flexible shape customization
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Strong internal structure due to aligned grain flow
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Quick lead time for prototypes and small-batch parts
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Ideal for heavy-duty industries like wind energy, mining, and port machinery
Applications
Our free forging products are widely used in:
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