Die forging is a technique for creating a part by applying significant force to a hot or cold metal bar to make it take on the required shape. It enables tolerances to be obtained that are very similar to what can be achieved by direct machining, but in addition the parts obtained have greater resistance to mechanical stresses as the deformation of the metals causes cold working, which itself causes grain flow in the metal.
grain flow
The main advantage of drop forging as against foundry is the forming of the internal structure of the material, resulting in better mechanical properties. It is currently the only technology capable of complying with standards ISO 7206-4 and ISO 7206-6:2013 on fatigue tests on forged hip prostheses.
Cast parts that are highly loaded, particularly in fatigue, must therefore often be over-sized in relation to forged parts.
Structure of a part obtained by casting
Machining is carried out in the unprocessed raw material. When it is delivered this raw material always has a lengthwise grain structure. This is associated with the process for producing the bars of raw material.
When the parts are machined in this unprocessed material, the grain structures are cut, which compromises the mechanical strength.
Directly machined parts that are highly loaded, particularly in fatigue, must therefore often be over-sized in relation to forged parts.
Structure of a part obtained by machining
FORGINAL medical uses Montbard board drop hammers: 850 kg, 1,000 kg and 1,250 kg. This type of equipment, unlike screw or hydraulic presses, enables us to offer anatomical prostheses with a thickness tolerance of up to +/- 0.1 mm, a precise and regular finish for parts, in particular on all shoulder prostheses with ridges or teeth, and a much lower raw material usage weight than with other forging technologies (approximately 20% less).
The turntable heaters are all computer controlled, which ensures total consistency in the preparation of each billet before forging. This is particularly critical for titanium parts, where a temperature difference of just a few degrees from the setpoint can cause major defects.
We also offer the special service of forging very small series starting at 25 parts.
This flexibility comes from the choice of not automating certain production facilities; the time it takes to set up automated equipment is justified only in the case of long production runs. As an example, FORGINAL medical has opted for manual drop hammers, for which set-up times are particularly short.
FORGINAL medical is your subcontracting partner. It is dedicated to manufacturing your parts in strict compliance with your requirements and specifications.
Our know-how lies in the way we support your projects and our expertise in manufacturing hip prostheses.
FORGINAL medical does not therefore have its own range of implants on the market. We concentrate on making your projects happen and producing your tailor-made ranges of forged implants.
