High-Strength Forged Heads, Shafts, and Fasteners with Dimensional Precision
Manufyn offers precision upset forging services for manufacturing robust and dimensionally accurate components like shafts, bolts, rods, and bars. With advanced upset forging machines and in-house die capabilities, we produce high-volume forged parts that meet mechanical, metallurgical, and durability standards.
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Upset forging is a metal forming process where a heated section of a workpiece is compressed to increase its diameter by decreasing its length. This method is used to create enlarged sections at the ends or along the length of components, such as bolt heads or flanges.
The upsetting forging process delivers stronger components with improved fatigue resistance due to controlled grain flow and reduced material defects.
Manufyn follows a streamlined and repeatable upset forging process:
A metal bar or rod is heated at specific zones using induction or furnace systems.
The heated section is placed into a die of an upset forging machine.
A ram applies axial force, upsetting the metal into the die cavity.
The part is cooled, trimmed, and optionally heat-treated or machined.
Upset
Understanding the upset forging advantages and disadvantages can help in selecting the right forming technique.
Produces stronger heads, flanges, and step features
Excellent for fasteners, shafts, and structural parts
Precise control over grain flow and material density
Minimal flash and material waste
Compatible with a wide range of metals
Limited to symmetrical or axis-oriented shapes
Requires careful heating control to prevent cracking
Tooling setup cost is higher for low volumes
At Manufyn, we help clients decide between upsetting in forging and other processes based on design complexity, load requirements, and production volume.
We use precision KDK upset forging systems for high-speed, high-quality component production.
Our engineering team creates custom die sets to suit part specifications and performance needs.
Upset forging improves internal structure and fatigue life, ideal for load-bearing components.
We forge carbon steel, alloy steel, stainless steel, and more, tailored to your application.
From forging to finishing, we offer end-to-end support with dimensional checks and NDT.
We manufacture a wide range of upset forged components, including:
Our upset forging services support demanding applications in:
Partner with Manufyn to tap into India’s manufacturing strengths. From prototyping to mass production, we offer tailored solutions that deliver quality, efficiency, and reliability, all at a competitive cost.
Get in touch with Manufyn to develop custom upset forging solutions for your fasteners, shafts, or structural metal components. We’re here to deliver performance, quality, and reliability at scale.
Upset forging is a process where the cross-section of a metal workpiece is increased by compressing its heated end or section, commonly used to create flanges, heads, and shoulders.
The upsetting forging process is used to manufacture bolts, rods, shafts, and other components requiring thicker sections at specific points.
A KDK upset forging machine is a specialized hydraulic or mechanical press designed to produce high-volume upset forged parts with repeatability and tight tolerance.
Advantages include strong, precise parts with excellent grain flow. Disadvantages include limited part shapes and the need for precise heating control.
Upsetting in forging is focused on enlarging specific cross-sections of a bar, unlike other forging methods that reshape the entire billet.
Carbon steel, alloy steel, stainless steel, and some non-ferrous metals can be used depending on application needs.
Upset forging is commonly used to make crankshafts, fasteners, step shafts, axle heads, and custom preforms.
Yes. With modern upset forging machines, this process supports consistent, high-speed production for large batches.
We offer close dimensional tolerances based on die design and material, along with optional secondary machining.
Yes. Upset forging is often the first step before closed die forging or machining for complex multi-step components.
