Patent ID: 7895873

Claim:
A method for simultaneously forging first and second parts, comprising the steps of: providing a forging die with a bottom part and a top part, said forging die having an inner forging cavity, an outer forging cavity surrounding the inner forging cavity, and a circumferential connecting opening between the inner forging cavity and the outer forging cavity and surrounding the inner cavity, a lower portion of the inner forging cavity in said bottom part being a single elongated shaft portion as a recess centrally located with respect to said surrounding outer forging cavity so as to form a single elongated shaft for said first part, and a depth of said elongated shaft portion of said inner forging cavity in said forging die bottom part being many times greater than a depth of a lower portion of said outer forging cavity in said forging die bottom part; placing a billet in a lower portion of at least one of the inner forging cavity, the outer forging cavity, and the connecting opening, and then with a forging press closing the forging die such that the die bottom part and upper part approach one another to cause material of the billet to spread throughout the inner forging cavity, the connecting opening, and the outer forging cavity, and wherein excess ingot material is forced out a circumferential excess material flow gap connecting to and surrounding the outer forging cavity at an exit region of the die; opening the forging die and removing a resulting unified forging part formed of an inner forging part and an outer forging part joined by a connecting region of material; and separating the inner forging part and the outer forging part at the connecting region to create said first and second parts and also removing an outer flashing of excess material from and completely surrounding said outer forging part.