Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.

A die holder mounts a die to form heads on nails or screws. A top surface of the die includes a groove for longitudinally receiving and holding an elongate body. The die has a recess merging into the groove at one end of the groove to form a nail or screw head. The die is conical for press fit by contact with an inner surface of a bore or hole in the die holder. A top surface of the die is planar to a top surface of the die holder with a bottom surface engaging bottom part of the die holder. The bottom portion of the die has a recess or engaging with a corresponding protrusion die holder fixing an angular orientation of the groove relative to the die holder. Two opposite dies are brought together by two opposite die holders forming the head.

A die holder mounts a die to form heads on nails or screws. A top surface of the die includes a groove for longitudinally receiving and holding an elongate body. The die has a recess merging into the groove at one end of the groove to form a nail or screw head. The die is conical for press fit by contact with an inner surface of a bore or hole in the die holder. A top surface of the die is planar to a top surface of the die holder with a bottom surface engaging bottom part of the die holder. The bottom portion of the die has a recess or engaging with a corresponding protrusion die holder fixing an angular orientation of the groove relative to the die holder. Two opposite dies are brought together by two opposite die holders forming the head.

Provided are a Ni-based alloy for hot die having a high high-temperature compressive strength and a good oxidation resistance and being capable of suppressing the deterioration in the working environment and the shape deterioration, a hot forging die using the Ni-based alloy for hot die, and a method for manufacturing a forged product using the hot forging die. The present invention provides a hot forging die comprising a Ni-based alloy for hot die comprising, in mass %, W: 7.0 to 15.0%, Mo: 2.5 to 11.0%, Al: 5.0 to 7.5%, Cr: 0.5 to 7.5%, and the balance of Ni with inevitable impurities, wherein at least 80% of a surface area of the Ni-based alloy for hot die is covered with an aluminum oxide layer. In addition to the composition, the Ni-based alloy for hot die may further comprise 7.0% or less of Ta and may further comprise one or two or more elements selected from Zr: 0.5% or less, Hf: 0.5% or less, rare-earth elements: 0.2% or less, Y: 0.2% or less, and Mg: 0.03% or less.

Provided are a Ni-based alloy for hot die having a high high-temperature compressive strength and a good oxidation resistance and being capable of suppressing the deterioration in the working environment and the shape deterioration, a hot forging die using the Ni-based alloy for hot die, and a method for manufacturing a forged product using the hot forging die. The present invention provides a hot forging die comprising a Ni-based alloy for hot die comprising, in mass %, W: 7.0 to 15.0%, Mo: 2.5 to 11.0%, Al: 5.0 to 7.5%, Cr: 0.5 to 7.5%, and the balance of Ni with inevitable impurities, wherein at least 80% of a surface area of the Ni-based alloy for hot die is covered with an aluminum oxide layer. In addition to the composition, the Ni-based alloy for hot die may further comprise 7.0% or less of Ta and may further comprise one or two or more elements selected from Zr: 0.5% or less, Hf: 0.5% or less, rare-earth elements: 0.2% or less, Y: 0.2% or less, and Mg: 0.03% or less.

A forging tool is to forge a workpiece in a cuboidal forging space, and wherein (a): the forging space is formed when the bottom surface of the first die and the bottom surface of the second die are brought into contact with the contact surface of the third die, or (b): the forging space is formed when a first die contact surface provided in the first die and a second die contact surface provided in the second die are brought into contact with each other.

A method of processing a material by use of high kinetic energy comprises a piston driven from a start position by a hydraulic system pressure by a drive chamber, by only one stroke, to transfer high kinetic energy to a blank/tool to be processed, whereafter there is a risk that a rebound of the piston will occur, so a step is taken in connection with said stroke performed, to prevent said piston from making a rebound with an essential content of kinetic energy to avoid negative effects as a result, whereafter the piston is returned to said start position by means of a second chamber, wherein a valve means closes the driving connection between the system pressure and the piston, the valve means is controlled by a pilot valve controlling the entire striking progress, and the second chamber is pressurized with the system pressure during the entire striking progress.

A method of processing a material by use of high kinetic energy comprises a piston driven from a start position by a hydraulic system pressure by a drive chamber, by only one stroke, to transfer high kinetic energy to a blank/tool to be processed, whereafter there is a risk that a rebound of the piston will occur, so a step is taken in connection with said stroke performed, to prevent said piston from making a rebound with an essential content of kinetic energy to avoid negative effects as a result, whereafter the piston is returned to said start position by means of a second chamber, wherein a valve means closes the driving connection between the system pressure and the piston, the valve means is controlled by a pilot valve controlling the entire striking progress, and the second chamber is pressurized with the system pressure during the entire striking progress.

A forged crankshaft manufacturing apparatus processes a forged blank with no flash. The forged blank includes at least one rough crank arm having an excess portion protruding from an outer periphery of a side portion thereof. The manufacturing apparatus includes a first die and a second die paired with each other, a retaining device, and a moving device. The first die and the second die bend or crash the excess portion. The retaining device retains at least one of the rough journals or at least one of the rough pins such that a rough pin decentering direction is perpendicular to a reducing direction in which the first die and the second die apply force for reduction. The moving device supports the retaining device such that the retaining device is movable in the reducing direction.

A forged crankshaft manufacturing apparatus processes a forged blank with no flash. The forged blank includes at least one rough crank arm having an excess portion protruding from an outer periphery of a side portion thereof. The manufacturing apparatus includes a first die and a second die paired with each other, a retaining device, and a moving device. The first die and the second die bend or crash the excess portion. The retaining device retains at least one of the rough journals or at least one of the rough pins such that a rough pin decentering direction is perpendicular to a reducing direction in which the first die and the second die apply force for reduction. The moving device supports the retaining device such that the retaining device is movable in the reducing direction.