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.
The new Hydraulic Press 4.0 technology Intelligent Manufacturing
Discover the Benefits of Intelligent Manufacturing with Mecolpress Hydraulic Presses - Technology 4.0
Returning from the EMO Fair in Hanover, our new hydraulic press ME 100.
Mecolpress has always been part of this event, and this edition has also been an important event for us, where we met many visitors from all over the world.
The digitization of industrial production has been the leitmotif across all Emo 2017 booths.
Industry 4.0 is a major process of global interest and also Mecolpress has presented its new ME100 hydraulic press, offering solutions for Industry 4.0 and integrated production.
La nostra nuova proposta è una pressa idraulica compatta SuperVeloce per la forgiatura di pezzi complessi a basso peso che assicura un altissimo livello di produttività, possibilità di stampare parti con forature multiple, forgiatura in singola o doppia figura, in verticale, in orizzontale e con ogni angolo billetta.
Our new proposal is a super-fast compact hydraulic press for the forging of low-weight complex parts that ensures a high level of productivity, the ability to forging multi-punched parts, forged single or double shape, vertically, horizontally and with each billet angle.
Mecolpress has developed this innovative machine, which will become part of the well-known series of presses ME, will have the code ME100-4L-30. This machine responds fully to our customers’ Industry 4.0 requirements and the general market for a press that features high precision features along with flexibility, ease of configuration and control of the production process.
Another important news was The brass bars heating+shearing furnace GBH5000, which allow great precision and modularity, in fact to connect both to new and existing presses, hydraulic, mechanical and screw.
Like all our ME series hot-press hydraulic presses, the new ME100 also allows you to control the speed, sequence, stroke and strength of each punch, enabling some of the most complicated forms to be forged flash-less.
The production phases are programmed and monitored to get the best shape.
Read more about the 4.0 requirements of our machines..
Mecolpress also puts you at your disposal a powerful production analysis software tool that allows you to perform statistical analysis of the forging process. This greatly reduces the waste of time and resources due to the production of non-conforming productions.
Read more about our software Calipso Statistical Process Control.
We are very pleased with the success of the news we have presented, but we are already committed to new extensions of our range of presses and also accessories for special applications. Follow us to stay up to date.
We thank all the visitors and the staff who took part in the event. We remind you of the next appointment:
CO-ENGINEERING TO DEVELOP MECHANICAL PRESSES
Co-Engineering makes it possible to create customized Mechanical Forging Presses and Hydraulic Presses
Mecolpress manufactures mechanical presses, hydraulic presses, used mechanical presses and used hydraulic presses, carefully revised, developing projects and new ideas from a close and constant collaboration with their customers and carefully selected partners.
This allows you to make great initiatives based on the professionalism, seriousness and trust of those who collaborate, sharing the best of the technological skills and design capabilities of everyone.
Mecolpress designs and constructs totally a complete range of hot forging machines such as: mechanical presses, hydraulic presses, friction and electric screw presses, trimming presses and knuckle joint press.
Through a co-engineering activity he also succeeded in offering complete forging systems that could include:
- Anthropomorphic robots
- Design of pneumatic and electronic arms based on customer requirements
- Transfer systems for forging
- Integrated or press-independent dies lubrication and cooling systems
- Forged pieces cooling systems
Mecolpress is responsible for the direction and coordination of the works.
As CEO, we are able to ensure continuity, support, and timely advice.
What enables Mecolpress to be at the forefront of Co-engineering activities designed to produce hot forging machines?
- the high number of projects completed,
- our experience in hot forging started in 1969,
- our constant presence on international markets.
All this has allowed us to gain considerable experience in the industry and to offer reliable service.
Getting a perfect forging solution becomes possible with Mecolpress:
- We reach an objectives set with the customer,
- We continually seek innovative solutions to achieve the perfect shape forming technology,
- Our R & D team is constantly committed to meeting the different needs of the customer.
These have always been the cornerstones of our mission.
The presence of Mecolpress at EMO2017
Mecolpress is constantly participating in EMO at every edition of this event, and this year will bring to the fair its most important innovations that will attract the interest of thousands of visitors.
Especially Mecolpress will show EMO2017 for the first time a newly conceived product, a compact hydraulic press for the forging of complex low-weight pieces that ensures a high level of productivity thanks to the different single or double forging solutions that ensures at each corner.
Mecolpress has developed this innovative product that will enrich the lucky series of ME presses ME100-4L-30, based on the many expectations of its customers and the market in general towards a work center that could present high-precision features along with flexibility, ease of configuration and control.
Other innovations that will be presented at EMO2017 are the GBH5000 stand-alone ovens that allow great precision and modularity, effectively connecting to both new and existing presses, hydraulic, mechanical and screw, of Mecolpress or any other manufacturer.
The new hydraulic press with heating-cutting bars online
Presentation of new hydraulic press ME100 / 4L30 with with very high productivity,
Heated+Cutting Bar on-line
The new compact hydraulic press ME100-4L-30 dedicated to the forging of complex shapes with low weight, with extremely high productivity.
The new machine is an evolution of the well-known and appreciated Mecolpress ME hydraulic machines, installed and working all around the world, from Japan, through Korea and China, up to Germany and Italy.
Features:
- Multiples coring possibility, single or double shape forging (parallel or head-to-head), in vertical, horizontal and at any angle.
- Advanced motion solutions to grant highest speed and the most precise control.
- Designed with focus on fast set up and easy access, maintenance and cleaning.
The brass bars heating+shearing furnace GBH5000 is what the market is since long waiting for:
a bar heating furnace, that at the same time can shear into billets, built as a stand-alone unit.
Advantages:
– independent from the press, as furnaces have always been: can be connected to new or existing presses, hydraulic, mechanic or screw presses, and loading automation, of whatever brand;
– allow the user the best flexibility in the production organisation and company development;
– for all lengths of bars up to 5 meters;
– no problems with small diameters;
– no damaging of the brass grain structure because of long-time high-temperature heating.
We will preview the machine at EMO 2017, follow the event.
Die Lubrication in the new generation of presses
In the most modern presses, like the continuous cycle eccentric SEO-CVE-CS or the hydraulic presses of the ME range:
- The mix oil+graphite is “pulled out” by the compressed air exiting the spraying point.
The lubrication fluid and the air are flowing in two concentric pipes, from the distribution blocks of the single lines to the application or spraying point.
For each of the points, the control is independent and it is therefore possible to decide for each one, from the operator panel:
- How long to spray air only (for example to reduce the temperature of the die and clean it from small burrs);
- How long then to spray air and the oil+graphite mix;
- How long at the end to blow again air only, to spread the lubricant and avoid thick deposits.
- The lubricant reach the application point through the press structure, the base (subpress) onto which the die is positioned, and through the die itself, all of them foreseen with channels and holes to reach the right points without losses and without spraying where it is not needed.
- Having the lubricant flowing through the machine and the die allow high time saving, because there is no more the need to reposition the and re-bend the singles pipes.
A modern and well thought press must in any case always allow to work with the pipes (Read previous article), that are still useful in case of work with third parties dies, or small batch testing with older dies.
It is even possible to modify existing dies, at the purpose to improve the performances and the precision of the lubrication, and adapt these for less modern machines to have internal lubrication channels.
Furthermore, from the operator panel, it will be possible for each lubrication point, to select if it should work as:
Upper die lubrication point;
Lower die lubrication point;
Punches lubrication point.
Each one of these settings offer specific pre-programmed activation conditions, each single point with its working time for air blowing, oil spraying…
Moreover, in our hydraulic presses ME the lubrication fluid is kept mixed and if necessary heated up in the power unit tank.
It is also important to know that the distribution line is built as a ring.
What does it mean? That the lubricant is always moving in the pipes, and it is therefore excluded every possible problem like lines clogging or lubricant cooling down too much, because the fluid is not staying in the pipes waiting for a valve to open, but continuously run around.
Moreover, there are control manometers at the beginning and at the end of the line, to keep the pressure at a constant level independently from how many spraying points are activated simultaneously.
ADVANTAGES OF THE LUBRICATION SYSTEM:
- Less waste of lubricant materials;
- Tool set-up time extremely reduced;
- Zeroing of the possibility of wrong or imprecise position;
- The lubricant is always moving, it is not staying in the pipes waiting for a valve to open: it is therefore excluded every possibility of clogging of the line or cooling down too much of the fluid;
- The pressure in the circuit is kept constant thank to the control manometers.
All of this is thought to grant to your forging process the “right lubrication”.
Industry 4.0
Hot forging becomes 4.0.
Our machines meet the requirements of industry 4.0.
The ME series hot forging hydraulic presses allow to control the speed, the sequence, the stroke and the force of each punch, allowing to print without any burr even some of the most complicated shapes. The production phases are programmed and monitored to get the best shape.
WHAT WE PROPOSE WITH OUR INDUSTRY 4.0 MACHINES?
- We program what the press must do;
- We program tolerance limits around a test cycle;
- We can control what the machine has actually done;
- The system verifies that the process is stable and identifies irregular anomalies or tendencies of deviation;
- We supervise and record parameters for at least 10,000 cycles;
- We provide a graphical representation of the process;
- All information can be sent to an external PC for further evaluation, registration and quality assurance purposes;
- The machine can send personalized messages to the supervisor, via email, to have full control over the performance of the equipment.
RESULT:
- To get precise analyzes and to make correct decisions;
- Have an automatic selection between compliant printed parts and irregular parts.
By ordering one of our machines you will be able to take advantage of the 250% hyper-depreciation. Contact us for further information
Flexible machine
In the industry, in the last ten years, pushed from the automotive sector, new production methodologies according to the Lean concept are becoming more and more common: in particular, companies that can be competitive on small production batches (producing only what is necessary) instead of manufacturing high quantities at low prices, with the risk of keeping high stock levels, are rewarded with success.
If in the automotive sector this method is since longer time a consolidated strategy, in the HVAC and sanitary industry this tendency has spread out slowly and in a non standardized way, mainly due to the high number of small sub suppliers for hot forged components.
From the bigger players the urgency toward the machine manufacturers is in any case very evident: more than high-productivity equipment, are the machines that can grant very fast set-up and extremely short production change-over time the most requested units.
The second must of the “Lean” work methodology is the zeroing of the waste and dispersions, or in other words, of the useless productions because of defected parts.
To this goal, the most requested ability of the machine is the always deeper control of the forging process: the machine must be able to collect, read and control as many as possible forging parameters, which are crucial for getting a stable-quality output. The machine must as well record these parameters, first to carry out statistical evaluations on the recurrence of deviations from the set standards, and second to allow to conduct analysis (at least at batch level, since the products are not singularly marked and identified) even on later stages, in case of customer complaints.
Mecolpress has in the production program a series of forging presses that are fulfilling in total the above-mentioned requirements:
the ME hydraulic presses range.
The hydraulic presses are designed to reduce the batch change time.
Hydraulic Presses – Parameters
The machine can control several process parameters and through these can manage the logic of defect pieces or generate statistical analysis with the recorder values.
The most important parameters are:
- Temperature of the billets to be loaded: a stable temperature of the billets grant a a constant forging quality and has direct influence on all other forging parameters.
- Coring punches penetration time: it is a good marker of the correct execution of the forging process, being directly connected to the energy required by the piece during the whole penetration stroke.
- Punches real penetration force: gives information similar to the coring punches penetration time, and is influenced by the same parameters.
- Final position reached by each punch: it is the most important parameter to judge if a piece is good or must be scrapped. Excess or lack of material are actually influencing this position, as well as loaded billet with not-correct temperature.
The ME Series machines have all features to be competitive in a controlled, modern forging plant, and perform best on medium and small production batches. These machines can be equipped with gas, or even better with induction furnaces, and with these are suitable to forge diversified materials: brass, aluminium, steel, copper, titanium. As an optional, dies thermoregulation units can be integrated with the machine.
