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 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.