Abstract: Methods and apparatuses are disclosed for heating workpieces that are to be warm forged into parts having integral portions of different configurations, such as reduced portions and upset portions. The corresponding portions of the workpieces are heated to different temperatures in a zone heating apparatus such that the reduced portion is formed before the upset portion is formed when the part is formed from the workpiece in a single forging stroke of a forging press. The zone heating apparatus may include spaced heating coil assemblies, each having a heating coil. Workpieces are pushed through the heating assemblies of the zone heating apparatus in steps, with one portion of each workpiece undergoing more heating cycles than the other portion.

Abstract: Methods and apparatuses for near net warm forging relatively small, complex shaped parts, such as automotive rocker arms, is disclosed. Die and punches are provided, which collectively have surfaces corresponding to the surfaces of the as-forged parts. Centralized workpieces, e.g., a transverse cylinders having a length-to-diameter ratio of approximately 1:1, are placed in cavities of the dies, and the punches are cycled through forging strokes to form the as-forged parts. The as-forged parts may have draft angles of 0-2.degree. and surface-to-surface transitions with radii of less than or equal to about 1mm, and may also have substantially parallel side surfaces.

Abstract: A female die of a closed die set for use in near net warm forging a part includes a cavity having a tapered upper portion and a lower portion. The upper portion is configured to support a workpiece at a preliminary position in the cavity, and to cause the workpiece to be pre-bent as it is moved through the upper portion of the cavity by a punch. The lower portion has a constant length and width so that the workpiece remains in the pre-bent shape during movement through the lower portion to the bottom end of the cavity. The workpiece is finally formed at the bottom end of the cavity to produce the part.

Abstract: A female die and a punch for forming relatively complex parts from axi-symmetrical workpieces, and the method of using the female die and punch to form the parts from the workpieces are disclosed. The female die and punch are used in a forging apparatus to near net warm forge parts that include curved surfaces with at least one protrusion offset from the longitudinal central axis of the part, or other complex part configuration. The female die includes curved inner surfaces that form the curved surfaces on the part and a recess to form the protrusion. The punch includes a forming surface at the bottom that is shaped to move material of the workpiece into regions of the cavity that form the protrusion. The volume of the part is substantially equal to the volume of the workpiece.

Abstract: A female die of a closed die set and a punch for near net warm forging complex shaped parts such as lugs from axi-symmetrical workpieces are disclosed. The punch includes a bottom forming surface having opposed chamfer surfaces which move workpiece material laterally in the cavity, prior to and during warm forging, such that the die cavity is substantially evenly filled. Consequently, the resulting parts are evenly filled without requiring that the workpieces fit snugly in the die cavity.

Abstract: A machine for fabricating heating structures having heating wires with an external layer of thermoplastic material arranged with sections in a predetermined pattern, and carrier strands of thermoplastic material fused to and interconnecting the wire sections. The machine includes a wire support means having laterally spaced pegs or the like on which the wire is retained in a predetermined configuration on a substantially common plane. A heating unit or units simultaneously heat the carrier strands and wire sections together. The heating elements and wire configuration are moved relative to one another to join progressively the strands to the transversely arranged heating wire sections. The element used in the heating unit includes a guide trough for the carrier strands and simultaneously heats facing surfaces of the strands and heating wire so that the two can be pressed together while fused to form the bond.