The “possessed” screw press
Even when some machineries present complex problems and when it seems that no solutions are possible, Mecolpress thanks to the solid technical skills that have always characterized it, can solve the situation. A specific case is what happened to a customer of ours and to his malfunctioning screw press. Read all the article to discover the details.
Screw press criticalities
Not long ago we were contacted by an Italian company specialized in the production of spades, shovels and other gardening tools. They bought a second-hand screw press from a competitor of ours because they needed to automate the forging line for spades and shovels by means of robots. Unfortunately, immediately from the beginning, some problems of machine malfunctioning were observed.
Indeed, the screw press just after three or four working hours lost capacity of hit till to stop completely and in addiction it consumed excessively the leather belt that had to be replaced even three times per month.
It really seemed to be “possessed by demons” and even who sold the machine could not solve the problem in the first instance, even though the numerous technical interventions that were carried out.
Since they could not repair in no way the machine and thanks to the suggestions of other machines suppliers, the company decided therefore to refer to Mecolpress hoping to find a valid technical support.
Mecolpress intervention
After a first telephone contact, our technician intervened directly on the press and after a first mechanical analysis he decided to dismount the main screw looking for the possible defect inside the machine.
After a half working day our skilled technician could identify the problem: one of the bronze ring was built with a wrong tolerance and as a result it caused an increase of temperature in the screw. Therefore, the materials expanded and led to a complete stop of the machine.
Our competitors could not even suppose this problem, while our technician in just a working day could identify exactly the reason of the malfunctioning.
This case study has shown how much it is important to have available all the projects and all the technical specifications of the machines which you want to operate on. The bronze ring of the screw press was realized according to a superficial mechanical analysis and to an insufficient knowledge of the complete design of the machinery.
Mecolpress has proved to have the necessary skills and experience to evaluate when a detail can make the difference. Indeed, even some unimportant details can cover a fundamental role in the optimal functioning of a press.
Our company has revealed once again to be a reliable and expert partner you can refer to for complex and apparently insurmountable technical matter.
EMO 2019: We unveil the technology of the future!
Mecolpress is ready for EMO 2019, the most important metalworking machinery fair, in Hannover from September 16th to 21st.
Mecolpress has always participated in EMO, the leading trade fair for the metalworking sector.
At each edition we always present some innovations, and this year more than ever!
On the Mecolpress stand there will be the possibility to see 2 machines running!
1- THE BRAND NEW HEAVY 400
Mecolpress will officially present the new HEAVY series of continuous cycle eccentric presses at EMO2019!
Its main features are:
- an extremely innovative and modern structure, more robust and also designed with an eye to ease and accessibility for maintenance and to safety;
- we have completely renewed die automation and lubrication;
- we have mounted a special hydraulic cushion that enhances the ability to forge cored parts, as well as to strongly reduce vibrations and noise;
- as on all our presses, also on the HEAVY series is installed Calipso, the intelligent software of Mecolpress for the analysis of the production process and for predictive maintenance.
The Mecolpress HEAVY Series represents the state of the art in hot forging with eccentric presses and can mount all the most modern accessories, production, programming and control systems.
2- The ME100/4L30 superfast – high productivity hydraulic press.
It is a compact machine, dedicated to the forging of small complex pieces, with an extremely high productivity.
This machine is the latest model of the now known and appreciated Mecolpress ME hydraulic presses, installed all over the world, from Japan to Mexico, from Korea and from China to Germany and Italy.
ME hydraulic presses have been for years a real innovation in the world of hot forging. They allow printing without flash thus significantly reducing material waste.
The ME100 / 4L30, like all Mecolpress hydraulic presses, is equipped with a powerful statistical process control software developed by us, called Calipso.
As stated by the official Hannover Magazine, this year EMO will focus more and more on digitization, with many insights and eyes still on the subject of Industry 4.
Among the most interesting aspects of Industry 4.0 there is undoubtedly the development of the so-called “platform economies”, also Mecolpress in this regard will present a new way of experiencing hot forging machines: connected in the cloud the press becomes intelligent, smart and easily monitored!
We will demonstrate how it is possible to integrate our presses with cloud or local applications that allow to carry out analysis of multiple operating and process parameters, thus representing, through dashboards, a real-time visualization for an optimal understanding of the data collected by the machine.
We will present all this at EMO 2019,
follow the event on our social media channels, we will soon reveal important news!
Friction or electrical screw press?
There are electrical or friction screw presses. Which to choose? The choice of the model is linked to the type of parts you want to forge, but also to the press performance. Discover the differences between these types of screw press by reading this article.
The mechanic friction machine is provided with a flywheel that rotates the screws clockwise or counterclockwise so that to let the slide go down or go up. In this case the transmission of the motion from the electric motor to the flywheel happens through the friction created on a leather belt. This model does not permit a direct control of the motor and of the flywheel, even if it presents considerable advantages in terms of energy saving. Indeed, a friction screw press has a medium consumption of about 40 KWh.
These presses require a smaller investment than the one of the screw presses with electrical servomotor, but they need the leather belt replacement, necessary for the slide movement when it wears.
Suitable for the hot forging of every type of material, the friction screw presses are used for the production of full parts.
This press, as opposed to the friction one differs for an electrical motor directly mounted on the flywheel, in the upper side of the machine, that rotates the screw. Thanks to this characteristic, the electrical screw press allows a better control of the productive process. Indeed, it is possible to check the descent and rise speed at any moment, to have direct feedback about the production of the machine and to calculate the necessary tonnage for the hot forging of parts you want to produce.
The electrical screw press requires more electrical energy, but its components wear less, and it is particularly indicated for the production of parts that require more strokes to be completed. In addition, it is possible to obtain much more energy with a reduced stroke, which does not always happen in the case of friction screw press. As a result, this machine has a rate of production slightly higher than a traditional machine.
The mechanical screw presses of Mecolpress TDS series are moreover provided with Calipso software, which is also developed by our company, that allows the data collection and recording in real time. In this way the end-user can do a process evaluation and intervene to optimize it.
Mecolpress proposes to its customers both friction screw presses and direct control with electrical servomotor control screw presses, developed to satisfy the different productive needs and suitable for the forging of full parts destined to sectors such as automotive, medical and sport one.
Mecolpress range of presses
For metals hot forging it is possible to use both mechanical and hydraulic presses. Mecolpress proposes high-tech and of different types machineries in order to satisfy nearly all production needs.
Mecolpress presses are indicated for copper, brass, steel, titanium and aluminum hot forging.
Mechanical presses
Among Mecolpress hot forging mechanical presses there are eccentric mechanical presses that are classified according to the nominal force. SOV model for vertical forging: they require an average energy consumption and are characterized by their high productivity. Instead, the SEO presses are developed for the forging of parts with coring and are divided in:
- SEO: (at single cycle): presses for forging with horizontal coring, high energy, medium Productivity
- SEO- CVE/CS: (at continuous cycle): presses for hot forging with horizontal coring, high energy, high Productivity
- SEO-F: (a ciclo singolo): (at single cycle): presses for forging with vertical coring, high energy and medium productivity
Another type of mechanical press offered by Mecolpress is the screw press.
The screw presses are divided according to the screw diameter and there are three available models:
- TDS: direct control with electrical servomotor. The screw diameter goes from 240 mm to 525 mm.
- Dellavia: friction discs control. The screw diameter goes from 130 mm to 460 mm.
- Osterwalder: friction discs control. The screw diameter goes from 150 mm to 220 mm.
Hydraulic presses
Our hydraulic presses are part of ME series and are characterized by their dies closing force that goes from 100 to 500 Tons.
These are the tonnages we have realized so far, but we can realize tonnages with greater closing force, as well. The horizontal coring punches force goes at present from 30 to 350 tons and also in this case, upon request, it is possible to produce the machine with a greater force than the indicated one.
Presses for parts coining and calibration
Mecolpress offers to its customers that need presses for parts coining and calibration the knuckle joint press of PG series, that are characterized for their low stroke and very high productivity.
These are classified according to their nominal force.
Machineries for parts trimming:
Mecolpress trimming machines are classified according to nominal force, as follows:
- PO:trimming machine with single station, low productivity, generally used for manual loading, H structure. Tons from 10 to 60.
- S: trimming machine with multiple stations, provided with rotary station with hydraulic motor. It is characterized by a medium productivity rate and it is used for manual or by automation loading, H structure. Tons from 10 to 60.
- E: Trimming machine with multiple stations, equipped with rotary table with electrical motor, high-medium productivity, more suitable for loading by automation or robot, C structure. Tonnage from 10 to 60.
Thanks to the variety of offered machineries, our sales department can suggest you the press that best fits for your project according to the type of part to realize and according to the specific conditions in which the customer operates.
Mechanical press or hydraulic press?
Thanks to the long experience as press manufacturers, Mecolpress can offer to its customers a wide choice of mechanical and hydraulic presses for hot forging and our sales department team can suggest the most suitable machine for the realization of a specific geometry.
Differences between mechanical press and hydraulic press
The mechanic press develops the movements necessary for forging thanks to mechanical connections between the ram and the horizontal coring system of the parts. The upper die close against the lower one and the punches enter laterally. The movements of the mechanical components are therefore all connected with each other and their planning results to be a little bit restricted because if you adjust the movement of a component, you will automatically modify the other ones, as well.
The movements of the components of the hydraulic press are adjusted by hydraulic cylinders instead and you will have an independent control on each axis. This implicates a superior programming flexibility because you can operate on the single components and obtain a better material flow management inside the die.
When it is better to choose a mechanical press
The mechanical at continuous cycle presses for metals hot forging have a higher productivity compared to the hydraulic presses, and this certainly represents an advantage.
There are vertical forged parts, such as the straight junctions or the nuts, that due to their shape are very suitable to be forged by high productivity mechanical presses.
When it is better to choose a hydraulic press
The hydraulic presses allow a major control on the movements of the single components and are more suitable for the realization of parts of complex geometry, such as the slide gate valves. The punches that contribute to the realization of the part are indeed independent and are generally four, placed at 90° of distance from each other, but one or even two punches can be set up with a variable angle of entry, for example of 45° compared to the adjacent one. This implicates a higher flexibility and the possibility to realize some very complex shapes maintaining a high-quality standard.
Another characteristic of hydraulic presses for metals hot forging is the fact that they need less structure inside the productive area because they do not need to be placed on a pit, that is compulsory for the mechanical presses. The positioning of the hydraulic press on simple floor allows a higher flexibility in the factory layout.
The best choice? Ask Mecolpress!
The choice to buy a mechanical or a hydraulic press is almost exclusively made based on the shape of the part to be forged and not based on the material. Both the presses typology forge indeed different types of metals. The only case in which the material can be a decisive factor refers to steel productions that often require the use of a screw press because of the high tonnage.
Mecolpress offers excellent mechanical and hydraulic presses according to the part geometry that the customer wants to realize, and suggests the best and most performing press, that can indeed optimize the production and sparing on the costs.
If you want to receive information regarding our hot forging presses, you can write to: sales@mecolpress.com
Mecolpress hydraulic presses: features and advantages
Mecolpress boasts a wide range of hydraulic presses of different tonnages, ideal for the realization of hot forged parts with complex geometry. The presses are equipped with a Mecolpress proprietary software, “Calipso”, that allows to monitor the entire productive cycle of the hydraulic press according to numerous parameters.
Features of hydraulic presses
Hallmark of every hydraulic press is the programming flexibility. Since the ram and the punches are independently controlled by hydraulic cylinders, this allows to carry out some corrections during the working cycle to remedy some eventual defects by acting on the movement of a single component through software.
Hydraulic presses can hot forge different materials including brass, copper, aluminum, steel and titanium alloys.
Range of Mecolpress hydraulic presses
Mecolpress offers to its customers a wide range of presses with a die closing force that currently goes from 100 to 500 tons and a minimum punch force of 30 tons that can arrive till 350 tons.
Moreover, our hydraulic presses are provided with a loading arm for warm billets and with an unloading arm for the forged part. Based on the customer’s needs concerning the layout for the hot forging production line, the arms can be placed on the same side and working in sync, otherwise placed on the opposite sides and working autonomously. Thanks to “Calipso” software developed by Mecolpress and installed on every hydraulic press, the press can detect which parts are not in compliance with the programmed parameters, and these parts will be automatically separated from the others by the unloading arm, flowing into a box for wastes.
This management allows to optimize the checks and to save time on the productive cycle.
Possible configurations of a hydraulic press
Mecolpress hydraulic presses can be set up in a custom-made way according to production needs expressed by the customer. For example, one or two punches can be placed with an entry angle different from the classic 90°, allowing the realization of particularly complex shapes such as, for example, Y-junctions and filter bodies.
Further possible configurations are:
- the addition of a fifth vertical punchthat operates under the die,
- the loading of one or two billets at the same time till a maximum of four,
- the addition of pyrometers for billet temperature detection,
- the application of extra sensors on the punches for both physical and mechanical data collection that are then sent to the PLC and that allow to better monitor the production cycle.
Indeed, the sensors always check the movement carried out by the punches during the stroke and it is possible to obtain a representation of the different acceleration and deceleration phases. This real time analysis allows to notice eventual problems and to understand if these derive, for example, from the die or if these are of hydraulic or mechanical type.
In this way also the Mecolpress service team can intervene in a more to the point and prompter way, reducing the machine stop costs.
Hot forging of the brass without flash, a success case
Brass hot forging and its application sectors
The hot forged brass pieces are used in many sectors, including, for example, clothing and constructions industry. The belt buckles, the zippers and door handles are all examples of parts produced with this material and obtained through hot forging presses.
Among the different application sectors, however, the one that sticks out mainly is the fluids control and hose fittings sector.
- Taps and fittings pieces,
- Valves for LPG tank and high-pressure gas,
- Ball valves for water, gas and oil,
- Watermeter bodies,
- Junctions for both the normal and floor heating, these are all brass pieces.
This type of product is currently affected on the market by a very strong competition of the Countries in which the manpower is cheaper and where probably in some cases a brass alloy is used that responds mainly to the local necessity and to the temporary availability, rather than to satisfy the international quality standard. To produce this kind of pieces in Europe, saving competitivity on the market represents therefore a challenge for many companies.
Hot forging without flash four brass parts at the same time
Speaking with a customer of ours who has the productive headquarter in Europe and who produces brass pieces, we could experience his real difficulty to remain on the market. From here comes the idea to find a solution that could allow him to increase the productivity and to reduce considerably the wasting material for sparing on the costs.
Our staff in collaboration with the technical office of the customer has identified then two different dies: one for the production of a hose junction connection and another for a curve of 90°. These new dies have been developed to take advantage of the potentiality of our hydraulic presses of ME serie of forging without flash and the result was to forge 4 parts at the same time.
In order to obtain this result, it is necessary to provide one of our standard hydraulic presses, such as the ME250/4G100, with some optional accessories (including also the billets loading system), that are conceptually simple but extremely well-performing.
This system is different due to its strongly innovative characteristic, since at the moment just the Mecolpress presses can provide this result (forging 4 pieces at the same time without flash) that surely brought great advantages also to our customer in terms of marginality on the product cost.
Through this specific press for the brass forging, it is possible to produce 4.500 parts at hour on average without flash.
This case study shows how it is possible to find solutions in the concrete and proactive collaboration with the customer that satisfy in the best way the specific productive necessities of that company and for its own specific interest.
Beyond the press: great care for all the manufacturing segments
The reasons why you should appreciate (and prefer…) the modularity
In the planning and realization of different forging lines there is a common denominator, and it is the main machine, the heart of the entire project: the press.
Even if it concerns aluminum or brass forging, the press manufacturer must have a broad view, that can contemplate the entire process, from raw material bars to the finished part. An optimum press has to be born “conceived” in such a way that allows it to be able to work in synergy with the other components of the line, in order to guarantee to the user the maximum efficiency and minimum wastefulness.
The most important manufacturer’s feature that every customer who buys machineries looks for is reliability: the certainty of providing themselves with a product that “performs”, that gives satisfactions and no worries. Obviously, the moment of the initial choice of the machine is crucial, and it is determined by understanding the variety and variability of customer’s necessities over time and by the manufacturer’s competence satisfying them.
And then, steps that cannot be considered “less” crucial will arrive: installation and activation of the machine, for example. These are moments you will spend calmly, if you have someone by your side that assumes wholly the responsibility to have delivered the machine, to have verified that it works during the entire working life of the machine, as expected by the costumer, since the manufacturer is present from the start up.
Putting effort into guaranteeing all this means to be completely “master” of their own technology and of all the components that compose the line, thought as many different “segments” of a whole. We all know that presses for working and going into production need accessories, like sawing machine, furnace, deburring machine…
The skilled press manufacturer knows how to give the right relevance to these segments, by addressing the customer to the most appropriate choice (both for technical characteristics and budget characteristics) for him, by offering the most correct solutions, even if these are supplied by the manufacturer himself or if these are reachable directly from the customer by other specialized manufacturers.
The habit to think and to study every single “segment” of the forging line so that it contributes to the best, in its peculiarity, to the line efficiency has a name: modularity. The numerous satisfaction “stories” of the “Top performer” customers indicate the modularity as the most efficient way to go.
How many elements, realistically, is the press connected to? The list is long:
- traditional gas heating furnaces,
- Induction heating furnaces,
- graphitizing machines,
- arms or external Robots and of third party for loading/unloading of the machine,
- trimming presses,
- sandblasting machines,…
In the face of a so articulate system, the experience shows us that the “compactness” is not enough.
There is no doubt that setting up a line according to the modularity criterion will request:
- Time and patience;
- active consultation of the manufacturer;
- the need of being informed and updated on the market proposals
- Once the choices are made and components are purchased, arranging the suitable places to place them.
But let’s resume exactly from here. The possibility to “save” spaces, indeed one of the main subjects of the offers of compact lines manufacturers, seems not to be a small advantage.
However, combining many specific machines in just a “compact” solution for the above-mentioned advantage to save space risks to compromise the production results. Unfortunately, the matter of fact is that a break of just one component is enough to stop the entire “compact line” activity. So, the risk is: I have optimized the space, but the banal breakdown, for example of a blade of the shearing machine could cause the stop of the total production. At that point, having saved space will not be a great consolation, unfortunately.
The style of modularity belongs traditionally to manufacturers who knows thoroughly the problems and matters that who forges must face every day. Who has this kind of knowledge also knows well that the fact of being able to intervene in a focused and independent way on every components of the line has no price.
The modular concept, that as we have already seen, provides to have the press in line but separated from the furnace and even not in line with the other machines (as, for example, the sawing-machine or the graphitizing machine, that working separately, can create “buffer” stock of semifinished parts along the line), it allows:
▲ The biggest flexibility: the customer can choose the components he prefers (gas or induction furnace, sawing machine or seaming machine…), changing them in the future to answer to new needs, and to adapt the line layout to a company that develops.
▲ The press, since it is independent from furnaces and sawing machine, can be used in the future for forging other types of brass alloy, or copper or aluminum.
If sawing-machine, furnaces and press are “melt” in just one machine, this is not possible.
▲ Every machine can give its best (a good sawing machine can cut more billets/hour than a press can print) and does not have to adapt to the speed of the slowest machine.
▲ The line will be able to be easily adapted to non cylindrical classic billets, but also, for example pre-bent, disc shaped, billets with special contour.
▲ The best efficiency: each machine is independent, the press can forge when the sawing-machine needs a blades replacement: on the contrary, when the die on the press is replaced, the sawing machine can continue to prepare billets.
A solid knowledge of the machineries is the fundamental base that allows the manufacturer to design and propose the best technical and economical solution for the customer’s needs. Since the manufacturer is specialized in the production of presses and since he is not obliged to provide with the press its own sawing/shearing machine and furnaces and not those of anybody else, will be able to suggest to the customer the best solutions to the specified needs.
The range of the proposal is very wide, and it is possible to range from new lines (in which each component is totally new and realized by the best specific manufacturer) to lines in which one or more parts are overhauled. But is welcomed also the costumer that, choosen the press manufacturer for trust and reliability reasons, then refers to him to have consultation and indications for the other components to add so to have a complete line, “ad hoc” both for the technical production requirements and for the “wallet” ones.
Regardless of your belonging sector: thermal-hydraulic, gas, automotive, railway, biomedical, special screws, clothing components, the modularity confirms always to be the winner, exactly for the flexibility that guarantees to the forging line and for maintaining its efficiency.
Complete Mecolpress Line for hot forging of metals
Complete line for hot forging of metals
Mecolpress has the abilities and the experience to develop complete forging lines.
We have designed and composed various forging lines, taking care of the whole project:
From the initial choice of the machines and related interconnections, to the installation and commissioning, taking full responsibility of the service and of the after sales warranty of the whole line.
Mecolpress therefore, in addition to in-house designing and manufacturing of the hot forging presses, is able to provide to the customer a full turn-key plant, from the raw material bars to the forged piece (including of course the eventual trimming, sandblasting…).
The productive core of the line is clearly one of our presses, being a mechanical or an hydraulic one.
In the video shown as example here below, you can see a line with a mechanical press of the SEO range.
Forging line with mechanical press SEO
Forging line with hydraulic press ME-G
The ME-G hydraulic presses are particularly suitable to be installed in a complete forging line.
Are machines specifically designed to be used in the hot forging of brass, but have already proved to be extremely flexible and therefore suitable for other materials as well, like aluminium.
With this kind of presses, Mecolpress has introduced in the year 2010 a fully new production method for the hot forging processes.
This technic, called “inverse extrusion”, allow to forge parts even with the most complicated geometries, where the deformation of the material is obtained by means of a pre-determined and controlled flow of material.
This is generated by a programmable advancing of the punches into the die, after that the pre-heated billett has put deposited in the die and this has been fully closed.
The ME-G hydraulic press can be connected and interfaced with:
- Bars sawing / shearing machines,
- Traditional gas or electric induction heating furnaces,
- Furnaces designed for the shearing of the hot bar,
- Automation arms or external robots and of third parties automations for the loading and unloading of the press,
- Flash trimming presses, sand blasting machines…
The interfacing possibility is very useful for example when, in case of an alarm from the furnace side, the press has to be put in a stand-by status and has to record the reason for the production interruption.
In turn, the ME-G can send to the furnace the information “start / stop billet feeding” and can exchange signal of operating status with other components of the forging line, as well as the production parameters with the customers’ own factory supervisor systems.
Soft-Impact hydraulic cushion for eccentric mechanical presses
A recent innovation by Mecolpress for eccentric mechanical presses.
Mecolpress proposes to equip the eccentric mechanical presses of an innovative hydraulic cushion, Soft-Impact.
Features:
- It is a real hydraulic cylinder with a stroke sensor on the shaft;
- Movements are fully programmable and controlled by means of proportional valves;
- Starts independently the down-stroke and then the punches move forward toward the die center before the upper die hits the lower one;
- Strokes adjustment from operator panel by simply inserting the desired dimensions and the data of die and die-holder heights;
- As alternative, the function “punches pre-start” allows the punches to move close to the billet before the die closes and the forging begins.
- Dedicated hydraulic unit, separated from the machine clutch one.
Thanks to the here above-mentioned features, the soft-impact hydraulic cushion allows the mechanic eccentric presses to achieve important results:
- Extremely simplified mechanical components;
- Precise adjustment from the operator panel of the start, stop and braking quota; all set parameters are saved together with the piece recipe;
- The upper die does not crash violently against the lower one, because it “reaches” the second one while it is already in the descending phase;
- The control system automatically calculates the speed and the moment to start the cushion;
- When the material deformation begins, the punches are already in an advanced position decided by the operator (it can be saved in the piece recipe); when the die re-opens, the punches then go back beyond the quota of work start;
- Separate blocks modular system.
Benefits:
- Less and simpler maintenance;
- Ease of use, machine set-up and perfect repeatability of forging’s cycles;
- Reduction of vibrations, resulting in general benefits for the press and for the working environment;
- Reduction of noise;
- Increased working life of dies and pins;
- No complicated calculations or measures for the operator;
- Possibility of reduction of forging defects due to material that goes out along the empty punch channels and then is pushed inside by punches starting their stroke too distant;
- Ease ejection of pieces (having an extra back stroke) without penalizing the cycle time;
- The oil in the cushion control unit has its own independent circuit and does not mix with the clutch oil, usually dirtier.
