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Hot Forge Upsetters

Hot Forge Upsetters

DiaManufacturerForge TonsGrip OpenStrokeSPMGrip TonsRef #:
1.1 "
29 mm
Hasenclever WSHK-100
Hasenclever WSHK-100
110 tons
100 tonnes
3.3 "
85 mm
7.1 "
180 mm
72
72
138 tons
125 tonnes
26090
26090
1.1 "
29 mm
Hasenclever WSHK-100
Hasenclever WSHK-100
110 tons
100 tonnes
3.3 "
85 mm
7.1 "
180 mm
72
72
138 tons
125 tonnes
26091
26091
2.5 "
64 mm
National
National
500 tons
454 tonnes
4 "
102 mm
9.5 "
241 mm
55
55
250 tons
227 tonnes
26158
26158
4 "
102 mm
National
National
800 tons
726 tonnes
6 "
152 mm
13.5 "
343 mm
35
35
400 tons
363 tonnes
24376
24376
4 "
102 mm
National (ATF)
National (ATF)
800 tons
726 tonnes
6 "
152 mm
13.5 "
343 mm
25
25
400 tons
363 tonnes
24625
24625
5 "
127 mm
National Double Toggle
National Double Toggle
1,100 tons
998 tonnes
7 "
178 mm
20 "
508 mm
33
33
550 tons
499 tonnes
24950
24950
5 "
127 mm
National Double Toggle
National Double Toggle
1,100 tons
998 tonnes
7 "
178 mm
20 "
508 mm
33
33
550 tons
499 tonnes
25722
25722
5.9 "
150 mm
Smeral
Smeral
1,323 tons
1,200 tonnes
8.5 "
215 mm
19.7 "
500 mm
27
27
463 tons
420 tonnes
26008
26008
6 "
152 mm
National
National
1,300 tons
1,179 tonnes
8 "
203 mm
18 "
457 mm
27
27
650 tons
590 tonnes
24889
24889
6 "
152 mm
Etchells
Etchells
1,100 tons
998 tonnes
6 "
152 mm
8 "
203 mm
30 to 60
30 to 60
1,100 tons
998 tonnes
24400
24400
7.5 "
190 mm
National Auto Tong Feed
National Auto Tong Feed
1,800 tons
1,633 tonnes
9.5 "
241 mm
22 "
559 mm
20
20
900 tons
816 tonnes
24709
24709
9 "
229 mm
National
National
2,250 tons
2,041 tonnes
11 "
279 mm
26 "
660 mm
25
25
1,125 tons
1,021 tonnes
24440
24440
10 "
254 mm
National Double Toggle
National Double Toggle
3,000 tons
2,722 tonnes
13.5 "
343 mm
30 "
762 mm
25
25
1,500 tons
1,361 tonnes
24714
24714

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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