Frequently Asked Questions

An FDFD (Four-Die Forging Device) is a tool that performs simultaneous forging of a billet from four sides on standard hydraulic forging presses with a force range of 2 to 150 MN. It combines the advantages of radial forging on radial forging machines (RFM) with traditional open-die press forging. The device mounts into an ordinary press and removes the need to purchase specialised equipment.

In conventional two-die forging, deformation is applied from only two sides, which gives uneven working of the metal and requires many billet rotations. The FDFD deforms the billet from four sides simultaneously and introduces additional intensive shear deformations.

• A more uniform, higher-quality metal structure;
• Deformation in the centre of the billet is higher than with two-die forging;
• Fewer rotations and passes mean higher productivity.

A radial forging machine (RFM) is expensive, specialised equipment that requires major capital investment and a dedicated shop. The FDFD delivers comparable four-sided working of the metal but mounts onto an existing hydraulic press and is far cheaper to implement than buying an RFM. You gain the quality of radial forging without acquiring a costly machine.

Applying force from four sides at once, together with additional intensive shear deformations, gives deeper and more uniform working of the entire billet cross-section. Deformation in the centre of the billet is higher than with two-die forging, so defects of metallurgical origin (porosity) are eliminated and carbides are distributed evenly. The result is a dense, homogeneous structure with improved mechanical properties.

Yes, FDFD technology is close in nature to isothermal forging. The intensive deformation generates deformation heating of the metal, which helps maintain the forging temperature. This reduces the number of intermediate reheats of the billet and lowers the energy spent on heating.

FDFD increases forging productivity by 1.5 to 3 times. In particular cases, forging time is cut by about 41–45 % compared with conventional technology, while the overall forging production cycle is reduced by 30–80 %. This is achieved through simultaneous four-sided deformation and fewer passes.

FDFD noticeably lowers energy consumption:

• Forging/drawing energy is reduced by 30–40 %;
• Metal-heating energy is reduced by 25–30 % thanks to fewer reheats.

The reduction in reheating is supported in part by deformation heating, which helps maintain the forging temperature.

Metal savings reach about 9 %, which amounts to up to 50 kg of metal per 1 tonne of forgings. Technological tolerances are reduced by 2–2.5 times and machining allowances by 1.5 times. This means less waste and lower costs for expensive alloys.

FDFD achieves dimensional tolerances within ±0.8–2.0 mm. At the same time, technological tolerances are reduced by 2–2.5 times and machining allowances by 1.5 times compared with conventional forging. This makes it possible to produce near-net-shape forgings and to reduce the amount of subsequent machining.

The typical payback period is about 4 years. In a real project with 20 MN and 25 MN presses, energy savings were around 35 % and productivity increased by 25–50 % when forging titanium aerospace alloys. Payback depends on the product mix, volumes and energy costs at the specific plant.

FDFD produces precise forgings of round, square, rectangular and polyhedral cross-sections — both solid and hollow, including stepped ones. The technology also suits variable-cross-section parts. Its high accuracy allows near-net-shape forgings to be produced.

FDFD forges all grades of steel and alloys, including hard-to-deform ones. These include heat-resistant nickel superalloys, titanium and zirconium alloys. Thanks to its intensive, uniform working, the technology is especially effective for materials that are difficult to process.

Yes. FDFD produces both solid and hollow forgings, including stepped parts and variable-cross-section parts. Precise four-sided deformation ensures uniform working even on geometrically complex sections.

FDFD technology is used in power generation, shipbuilding, the railway and aerospace industries, and in general heavy engineering. Typical products include:

• Ship propeller shafts;
• Wind-turbine components;
• Railway axles;
• Variable-cross-section forgings.

FDFD is compatible with standard hydraulic forging presses with a force range of 2 to 150 MN. The device is matched to the parameters of the specific press, so it suits both small and large production plants.

Yes. A key advantage of the FDFD is that the device mounts onto your existing hydraulic press without buying specialised equipment. We carry out the layout and design taking into account your press parameters and shop arrangement, so the device fits naturally into your current production.

A full change of the die set takes only 10–15 minutes. Such fast changeover makes it possible to switch quickly from one forging size to another and to work efficiently in small-batch, multi-product production.

Installing the device into the press takes about 3 minutes. This makes it possible to put the FDFD into operation quickly when needed and to free up the press just as quickly for other operations, without disrupting the production schedule.

Yes. Manufacturing is certified to ISO 9001:2015. This guarantees consistent quality in the manufacture of FDFD devices and compliance with international quality-management requirements.

To start a project, contact us and tell us about your press, your range of forgings and your objectives. Based on this information, we will propose a solution: we design the FDFD device, develop the forging technology and provide engineering support from design through to implementation. Flexible financing options with minimal initial investment are available on request.

The full turnkey package includes:

• Design of the FDFD device and development of the forging technology;
• Help in finding a manufacturer;
• Manufacture of the device;
• Installation and commissioning;
• Layout and arrangement planning to fit your existing shop.

After that, we provide long-term technical support and staff training.

Yes. We offer flexible financing options with minimal initial investment. This makes it possible to implement FDFD technology without a large one-off outlay and to spread the investment in line with the expected savings and productivity gains.

Yes. We support the project from design through to implementation and beyond. Our services include installation and commissioning, long-term technical support, consultations and staff training. Our team has more than 20 years of experience in forging and metal forming.

The implementation timeline is defined individually for each project and depends on your press parameters, range of forgings and scope of work — from device design and technology development through to manufacture, installation and commissioning. After reviewing your input data, we agree a phased schedule with specific dates. Contact us for an estimate tailored to your case.

Lazorkin-Engineering, LLC is an engineering company specialising in Four-Die Forging Devices (FDFD) and forging technologies. It is led by Dmitriy Lazorkin (General Director) and Viktor Lazorkin (Technical Director, Ph.D., an expert in metal forming and open-die and radial forging). The team has more than 20 years of experience and operates on the international market.

The company was founded in 1999 and has been developing and refining Four-Die Forging (FDFD) technology ever since. Over this time it has built up substantial practical experience and an extensive patent portfolio.

FDFD technology and the related forging solutions are protected by more than 70 patents, including international ones. This confirms the uniqueness of the developments and gives customers reliable legal protection for the technology they use.

FDFD systems are in operation in 11 countries around the world. In Europe these include Germany, Italy and Spain; in Asia, China, Japan and South Korea; and in the Americas, Brazil and the USA. This geographic reach confirms the international recognition of the technology.

For a technical consultation, contact us:

• E-mail: lazorkin.engineering@gmail.com
• Phone: +38 (067) 977-27-43
• Address: Ave. Soborny 182-a, office 28, Zaporizhzhia, Ukraine, 69035

Describe your press and forging tasks, and we will propose a suitable solution.