Open-Die Forging

Crusher Mantle Disc Blank — 950mm Round Open-Die Forging, Alloy 4140

A wide, comparatively short open-die disc forging for a mining crusher mantle blank — Ø950mm x 220mm in 4140 alloy, upset from round billet to develop the wide, flat cross-section a crusher wear component needs without the die cost of a closed-die impression.

Induction-heated steel billet glowing orange, prepared for open-die press forging

The project

A crusher mantle blank is a poor fit for closed-die tooling on a low-volume replacement-part order — the part's geometry is a simple wide disc, and dedicated die tooling for a shape this large would have added cost and lead time with no real benefit for a single blank. Open-die upsetting from round billet produced the wide, flat forged disc directly, which the customer then finish-machined in-house to the mantle's final wear profile.

The mining customer specified 4140 over a lower-alloy grade specifically for the combination of hardenability and toughness needed after quench-and-temper heat treatment on a wear component subject to repeated impact loading.