Hot Forge Upsetters

Upset Forging Machines (Upsetters)

What Does An Upset Forging Machine Do?

Upset Forging is a manufacturing process whereby solid rod or bar stock (tubing can also be used) is placed into an Upset Forging Machine, commonly known as an upsetter. Upset Forging is also known as either Hot Heading or as Cold Heading.

Rod or bar stock is clamped by a set of Open or Split dies one side of which is operated through the use of gripping toggles and cams which are capable of withstanding enormous gripping pressures. These toggles are interlaced and supported both in the grip slide and bed-frame which provides uniform bearing pressures. The toggles are usually the full height of the dies to support the grip dies from top to bottom.

While Clamping Force is being applied, the dies close exerting the full gripping pressure which holds the blank in place during the Forging Process. A forging ram with a series of heading tools impacts the end of the rod or bar stock and either reduces the diameter, pierces the part, or increases the size by gathering material and Upset Forging it into a particular shape. This process takes place in between one and five hits. Each time the part is forged, the dies open and the part is moved down to the next position where the dies again close to grip the part. Each new position is forged with a different heading tool which gradually forms the part until the rod or bar end reaches the desired shape.

Upset Forging Machines or Upsetters are ideal for forging longer parts where only the end of a rod or bar blank needs to be forged. In some cases, where both ends need to be forged, the rod or bar can be turned around and re-fed into the upsetter.

This process can be applied on either hot or cold material.

Although upsetters are generally designed with horizontal clamping where one of the two dies moves side to side, some are designed with vertical clamping where one of the two dies moves up and down as opposed to side to side.

Material to be forged generally ranges from less than 1" to up to 12" in diameter. On the smaller machines, parts can be hand-fed. In some cases, magazine or automatic tong feeding systems are used for the feeding of part banks into the upsetter prior to the forging process.

Parts Produced By Upset Forgers

Some of the parts produced using Upset Forging Machines or Upsetters are as follows:

• Fasteners such as bolts or screw head configurations
• Drive shaft Yokes
• Lug Wrenches
• Sucker Rods
• Suspension Parts
• Torsion Bars
• Spring Pins & Grease Cups used on Trucks
• Gear Blanks
• Transmission Counter-shafts
• Shell extractor pins
• Counter-shaft sleeve bearings
• Double Roller bearing races

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