Smart Brass Forging
We report the article below FIA Magazine, the Forging Industry Association, that speacks of us.
Smart Brass Forging
By Danilo Fagnani
MECOLPRESS started their activities in Brescia (Italy) more than 50 years ago, in 1969, providing solutions for the hot brass forging industry. MECOLPRESS then widened its portfolio including hot forging steel, aluminium, titanium, and special alloy applications. MECOLPRESS is now offering the most modern technologies available for mechanical (HEAVY family), hydraulic (ME Family) and screw driven (TDS, FPN family) presses.
The region of Brescia, located East of Milan, is generally considered the cradle of brass production, at least 20% of the total world production is firmly located here. The Brescia region is still able to compete with Chinese brass manufacturers (35% of the brass total world production) even if the production costs are not comparable in terms of manpower, energy and etc… The secret of this success is the know-how of the full brass production chain, industrially started from the 19th century, from melting process passing through forging then achieving the final product completion. MECOLPRESS was born and built in this interesting and dynamic environment, participating and contributing to solve the main challenges of brass producers (Smart Brass Forging).
These challenges are cyclically recurring in the market, and they can be summarized as follows:
- raw materials availability and costs;
- high variability in the market for parts from the peaks of high demand to small lots with frequent parts changeovers;
- difficulties to find the necessary manpower, from highly skilled operators, to maintenance technicians, to standard operations workers;
- availability to grant the best products quality reducing the non- compliant ones;
- reduction of the energy consumption approaching the green economy
MECOLPRESS is supplying to the market the most powerful hydraulic presses (ME family) offering horizontal\vertical coring performances achieving:
- flash-less forging;
- reduced part material thicknesses;
- deeper and deeper punch coring
These features drive achieving parts with less weight and avoiding any further downstream process as trimming. ME hydraulic presses family (more than 60 units supplied from 2010) has standard sizes:
- 100 to 500t as die closure force
- 30 to 350t of punch coring force
The coring punches have independent movement guiding and optimizing the flow of material inside the die’s cavity. The punches forces, speeds, displacement sequences can be flexibly implemented in the HMI operator panel depending by the products to be forged (Smart Brass Forging). One of the four horizontal punches can be orientable (without losing coring force!) with the variable angle from from 0 to 45° allowing sloping coring for the parts.
The ME family hydraulic presses grant production performances that, depending by the equipment size, can reach up to 30 cycles per minute and they allow to forge multiple parts per stroke, throughout of some thousands of parts per hour is easily achievable. This will allow to complete productions lots is shortest time even if they are relevant in the number of parts to be reached. If the market conditions are changing and the market moves to lower number of parts per lot with frequent shifting between the products, the quick dies changing system will allow to dramatically reduce the down time. The fully automatic tools locking\unlocking and the servo-moved supporting arms allow one operator to accomplish the change in the quickest time (about 15-20min), in the complete safety conditions and without the help of any tools (Smart Brass Forging).
Mecolpress ME Next Generation series hydraulic press hot forging EG coring tool
The MECOLPRESS policy to reserve relevant stock of spare parts for all the presses that have been supplied is a key point to avoid unwanted down time in case of maintenance of the equipment.
Mecolpress ME Next Generation series hydraulic press outstanding parts weight reduction
MECOLPRESS is developing all of the control software for the presses: CALIPSO (Smart Brass Forging). This user interface is based on a touch screen model, it is very easy and intuitive, and it has been developed in several different languages; it allows any end user operator to work with continuity on the press and it does not require any particular skills or knowledge. Many functions have been simplified as input parameter requests to reduce the human factor effect in the press working conditions. CALIPSO defines and controls automatically all the ME family presses operations, from raw material loading up to forged parts unloading. The main parameters of each product receipt are saved in the internal memory, and can be easily retrieved for future production and transferred to customer MES\MRP. The press has an Ethernet OPC-UA connection module that grants this function as well the remote teleservice assistance by the MECOLPRESS technicians.
The MECOLPRESS R&D department is able to define the optimized process parameters and/or the best die geometry through FEA software which allows them to analyze both material flow and forging force. This on-demand service is appreciated by customers who are searching for a reliable supplier.
ME hydraulic presses can be paired with all types of furnaces: billets, bars, natural gas, electric induction, keeping in mind that the reliability on the heating temperature, the billet weight tolerance and the material metallurgical microstructure properties are key parameters to grant effective flash-less process success.
High production capacity, flexibility to switch from one product to another and high equipment reliability vanish if the forging process is not under full control. CALIPSO software is leading the game supporting the customers to control, with minimal effort. The forging forces, punches displacement parameters and sequencies, billets temperature, and so on can be monitored in the maximum\ average values or continuously during the working cycle. The desired thresholds can be set in the system to monitor the trends of the parameters and if any mismatch is found, the parts can be diverted automatically to the dedicated collecting box for further checking.
MECOLPRESS is fully committed to be an effective part of the green transition of the industry, reducing the energy consumption, pollution emission, and media consumption. This application shall not decrease or compromise the outstanding powerful performances of the ME family presses. CALIPSO and in-house engineering are the main characters of this target:
- hydraulic auto-adaptive regenerative function circuits;
- ECO mode for working pressure optimization;
- actuators optimized geometry;
- flexible set up of the operating pressure;
- AC frequency converters\variable flow hydraulic pumps;
- CALIPSO software that learns from experience optimizes the working parameters without relevant operator required intervention (Smart Brass Forging)
Mecolpress ME Next Generation series hydraulic press main view
These points collaborate to reduce the energetic consumption up to 50% in comparison with standard technology presses.
The dies lubrication system, very important in the flash-less forging, is using innovative pipe to pipe technology supplying alternative air and oil flows just with the needed quantities. All the dies lubrication parameters are set into the control software and up to 30 points can be reached; they can be integrated into the dies or with external nozzles. The proper pumps are installed on the machine bottom to collect all the remaining quantity of oil avoiding any overflow. The press lubrication is selective and only the components active are reached by the media, proper collecting box avoid leaking. No more waste of fluids!
Pressa idraulica Mecolpress ME Next Generation: esempi di particolari stampati a caldo senza bava
Mecolpress ME Next Generation series hydraulic press four parts flash less hot forging examples
The innovative suction hood embedded in the press structure collects the emission very close to the sourcing point, decreasing any possible spread into the environment and granting the best cabinet inside view of the process to the operators.
As all MECOLPRESS products, the ME series fulfills the most severe international safety standards and can be produced in compliance with North American and Canadian ones.
Danilo Fagnani Sales Manager Mecolpress
Danilo Fagnani Sales Manager Mecolpress Spa
Phone: +39-030-2560110
Email: d.fagnani@mecolpress.com
EXHIBITIONS 2022: MECOLPRESS AT CASTFORGE (GERMANY)
CastForge 2022
Castforge Exhibition from 21 to 23 June in Stuttgart.
Today costumers of the “Casting and Forging” field are looking for high-quality products ready for installation. As complexity and specific requests are constantly increasing, it is essential to stay on top with the latest news.
This Exhibition represents an important opportunity to meet face to face and discuss these topics in one of the largest markets in Europe.
For this reason, from 21 to 23 June 2022 Mecolpress will be in Stuttgart at Castforge (Stand 5B57).
Augmented Reality, the press just a click away
On our stand it will be possible to view 2 Augmented Reality presses: ME hydraulic press and Heavy Mechanical Forging Presses.
This technology allows to add the multimedia virtual information to the actual view that is captured by the camera of mobile device, smartphone and/or tablet, enriching the surrounding viewing with additional digital contents.
Get your free ticket
To facilitate the visit and access in safety, it is appropriate to register to get the free admission ticket.
You can request it by simply filling out this form:
EXHIBITIONS 2022: MECOLPRESS AT BIEMH (Spain)
BIEMH Bilbao 2022
This event will be held at the Bilbao exhibition centre from 13 to 17 June 2022.
Mecolpress will present its latest technological innovations regarding metal forging.
Besides Spanish companies also international ones will be participating in this event, operating in sectors such as: metallurgy, welding, articles and equipment, machine tools, technological solutions, and much more.
You can find us in Pavilion n°5 Stand D34
Augmented Reality, the press just a click away
On our stand it will be possible to view 2 Augmented Reality presses: ME hydraulic press and Heavy Mechanical Forging Presses.
This technology allows to add the multimedia virtual information to the actual view that is captured by the camera of mobile device, smartphone and/or tablet, enriching the surrounding viewing with additional digital contents.
Get your free ticket
To facilitate the visit and access in safety, it is appropriate to register to get the free admission ticket.
You can request it by simply filling out this form:
Exhibitions 2022: Mecolpress at GLOBAL INDUSTRIE (France)
Global Industrie Paris 2022
In three editions, Global Industrie has established itself as one of the leading exhibitions in the world dedicated to industry.
Its resolutely modern positioning geared both to the industry of the future and to international business explains the success encountered by its previous editions held in even years in Paris and odd years in Lyon. A geographical diversification which enables it to enhance both its offer and the variety of its visitors.
Global Industrie returns to the capital from the 17th to the 20th of May, at Paris Nord Villepinte.
We are waiting for you Stand 6M91
Augmented Reality, the press just a click away
On our stand it will be possible to view 2 Augmented Reality presses: ME hydraulic press and Heavy Mechanical Forging Presses.
This technology allows to add the multimedia virtual information to the actual view that is captured by the camera of mobile device, smartphone and/or tablet, enriching the surrounding viewing with additional digital contents.
Get your free admission ticket
To facilitate the visit and access safely, it is advisable to register to get the free admission ticket.
You can request it by simply filling out this form:
HYDRAULIC PRESS, Mecolpress leap into a new eco-green modality
Main features of the new ME eco-green Hydraulic Press
Mecolpress S.p.a. is glad to introduce the new improved features of ME family hydraulic presses, born from the need to offer to the Customers a more flexible and performing machine in terms of product quality and energetic consumptions.
We are currently proposing the family of ME presses having the die closure force that is in the range from 100 to 500 tons (as standard equipment) and with a minimum side punches force of 30 tons that can achieve up to 350 tons. Each of these last ones has completely independent operation, adjustable speed and set-able movement phases (forward-stop-backward); depending by the type of part to be forged , the hydraulic closure cylinder allows to apply the necessary forging force also before the dies contact.
The new presses can be fed by one anthropomorphic robot for the billets loading and one synchronized unloading arm for the forged products that eliminate the set up difficulties of the traditional past technologies; regarding the fumes suction, after a careful analysis of the actual state of the art, we have implemented and optimized the system making it more functional and effective.
The fume suction hood collects the emission very close to the sourcing point decreasing any possible spread into the press cabin, granting to the operators the best inside view of the process and reducing the oil collection and its possible overflow.
In this regard, the machines of the new series are integrated with the walkable grids that surround the press and prevents the eventual drip on the floor of the working area.
The hydraulic presses can be supplied customized with optional equipment according to the production needs.
For example, one of the punches can be oriented with the coring angle that is different from the classic 90° configuration , allowing in this way the realization of particularly complex shapes, like y-joint or filter body.
Other possible configurations are of new ME eco-green Hydraulic Press are:
- the addition of a fifth vertical punch acting from under the die,
- the loading of one or two billets at the same time up to a maximum of four,
- the addition of a dies-holder arm lightening the machine tooling process,
- the addition of a quick dies changing system with hydraulic locking,
- the addition of an induction dies heating system which the machine is particularly compatible with,
- fire extinguishing system integrable with the machine.
Moreover the main innovation is related to the energy saving achievements if compared to the previous series.
From 2022 all the ME presses can minimize autonomously the energy amount that is needed to produce the desired forged part: the press learns automatically the optimal pressure to be addressed to each forging punch: ECO cycle (settable from the control panel). Furthermore, during the movement of each forging punch, Calipso control software optimizes the time in which it is necessary to switch to the maximum achievable pressure (regenerative self-adapting cycle function): all the press parameters will be consequently harmonized according to this requirement.
This behavior represents the key economic and competitive advantage for the press user that can save up to 50% of the total installed energy without losing or reducing the punches force and can optimize the forging process parameters in order to minimize the energetic consumptions. To do this the operator direct intervention is no longer necessary. The operator is not required to have a long term experience or particular skills : he will simply have to activate the ECO cycle from the control panel, ME press will care of the rest!
he will simply have to activate the ECO cycle from the control panel, ME press will care of the rest!
MECOLPRESS AT MECSPE 2021
THE EXCELLENCE OF TECHNOLOGY APPLIED TO INDUSTRY
It has been the most important event dedicated to innovations for the manufacturing industry and it counts 19 editions.
The fair will be held in Bologna from 23 to 25 November.
MECSPE, the main event in Italy on innovative technologies for manufacturing 4.0 industry promoted by Senaf, joins this outlook of restart and business confidence by following its commitment to support this sector and representing itself for 19 editions of over 2,300 exhibitors and trade associations.
This year’s appointment, rescheduled at BolognaFiere, from 23 to 25 November 2021, will have as its main theme “digitalization, training and sustainability”, subjects that visitors will be able to explore through 13 synergistic salons divided by thematic areas, demonstration of talent, commitment and creativity of Italian Companies.
A field, the industrial one, has always been supported by MECSPE which promotes fruitful collaborations between the various players in the supply chain, sharing visions and projects with them, as demonstrated by the historic partnerships with Confartigianato Meccanica and CNA Produzione.
At MECSPE 2021 we will exhibit the FPN 220 Turbo HS screw press.
This is the best evidence of the outstanding performances of the OSTERWALDER screw presses, part of by Mecolpress family from more than 20 years.
These screw presses are particularly suitable for processes where high precision\tight tolerances of forged components are required, for example in the production of gears. They are suitable for hot forging of steel parts, but also of all other materials.
The TURBO version allows to reach higher speed, increasing productivity from 20% to 40%.
Augmented Reality, the press just a click away
In addition to the FPN Turbo screw press, it will be possible to view two other technologies thanks to the Augmented Reality: the ME Hydraulic and the Heavy Mechanical Forging Presses.
This technology allows to add the multimedia virtual information to the actual view that is captured by the camera of mobile device, smartphone and/or tablet, enriching the surrounding viewing with additional digital contents.
Get your free admission ticket
To facilitate the visit and access safely, it is advisable to register to get the free admission ticket.
You can request it by simply filling out this form:
ForEMOst!
ForEMOst!
EMO is the worldwide exhibition of the machine tool, held in Italy and Germany, and that this year will take place in Milan at Fiera Milano Rho from the 4th to the 9th of October.
All the main international players of the manufacturing sector will take part in EMO MILANO 2021; so far there are more than 30 countries represented, covering all the segments that make up the world of the metalworking machines.
Undisputed leader in the trade fairs panorama, EMO represents the whole metalworking world in the best way, showing the best of vision and innovation.
Metal forming and metal cutting machine tools, robots, enabling technologies and automation, solutions for interconnected and digital factories, additive manufacturing will be among the key players of EMO MILANO 2021.
The exhibit is held in the entire Fieramilano Rho Exhibition centre, that can be easily reached with any transport means.
To guarantee visitors and exhibitors the participation in total safety in the exhibition, Fiera Milano Group has developed a Protocol for the safe conduct of trade fairs, in full compliance with the health rules and protocols issued at national level.
MECOLPRESS will participate with a “revolution” of the exhibition concept
Augmented Reality, the press just a click away
This technology allows to overlap multimedia information to the reality framed by the camera of mobile device, smartphone and/or tablet, enriching the surrounding viewing with additional digital contents.
A very powerful mean in the company communication field, and in this regard, the Augmented Reality has a strong impact on the customer experience, because it transforms the way in which companies interact with their customers.
In the trade fairs the Augmented Reality results to be very useful, both for the exhibitors and for the visitors who will be able to live a visual experience at 360-degrees.
Two will be the presses, chosen from the production range of MECOLPRESS, that will give birth to this innovative space of virtual reality, that will offer the possibility to see and to experience the functionalities of the represented machines.
We are waiting for you Hall 5 – Stand B29
Get your free admission ticket
To facilitate the visit and access safely, it is advisable to register to get the free admission ticket.
You can request it by simply filling out this form:
Cloud Presses
This year at EMO2019 we will give practical demonstration of how smart our machines are.
Created by Mecolpress for forging statistic control, Calipso is a software that allows to control the press activities during the entire production cycle, and it is an useful instrument for analyzing the production and for intervening where it is necessary to optimize it.
This intelligent software for the analysis of the production process also includes a sophisticated technology for managing non-conformity
Once all these data have been produced, it will be possible to log them, analyze them and import them into the customer’s management system.
For each machine cycle, a series of parameters are recorded on the operator panel, the last 10 cycles are displayed in tabular form.
Moreover, the parameters are recorded (the last 10000 cycles) and displayed in the form of trend.
Through the trend it is possible to carry out a cross-check, in order to idedntify the reasons of possible non-conformities.
An example:
At the EMO2019 exhibition in Hanover we present something more:
a practical demonstration, an example of how our machines can communicate with external systems and devices.
Thanks to the collaboration with the Smeup Industrial IoT department, it was possible to integrate our brand new HEAVY 400 mechanical press and ME 100 hydraulics with their IoT Platform.
The production information collected by Calipso can be viewed in real time through dashboards, for an optimal understanding of the data collected by the press.
Dashboards are created using a simple, intuitive and visually striking web tool. Looking at something that is happening at the very moment you are observing is very different from seeing deferred data. In a landscape where speed in making decisions is a determining factor, these tools offer an important contribution.
It is possible to monitor all this, in addition to the local one, also in the cloud: a very interesting aspect as it is possible, through a simple browser, to visualize the result through any instrument connected to the network, from the smartphone to the tablet to the PC, you can always take a look at the data collected, all in real time!
Monitoring the activity of the press, having the information that we are always interested in, getting important alerts or messages useful for example for predictive maintenance, is an interesting plus even for the forging sector that now more than ever becomes intelligent and in step with market demands!
Keep following us, the news will not be missing!
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!
Mecolpress hydraulic presses solve problems
Choosing the hydraulic presses of ME series for brass hot forging not only gives a technical advantage, but it can also represent a competitive advantage for your Company for the responsiveness on the market and for the speed your Company can reacts with to the unexpected necessities of the market.
This is the case of a customer of ours, Italian, based in Brescia, brass forger as subcontractor supplier for many years, with an increasing success thanks to the long experience of both the Company management and of the people in charge of the productive departments, first and foremost the brass hot forging one.
Experience and availability anytime
For years, quietly, without overdoing, but with perseverance and professionalism, our customer could manage optimally the different situations of the group, between forging and mechanical machining. Even if he is always looking for the hardest, most technical and logistic challenging orders, he could gain his position of full respect in the panorama of subcontractors (that are many in our province).
And in order to keep a high level of service and to receive in return a high loyalty of the customers, sometimes it is necessary to be able to take important decisions, in a very short time.
It happened so: in mid-November 2018, 15 days after they ordered us a 450 tons continuous cycle mechanical eccentric press, our customer had a meeting with one of his most important German customers, a very well-known company in the heating sector and civil hydraulic plants, who put on the table a series of new parts, in a brass alloy they invented, for which no one had forging experience.
In short, a challenge for our customer:
“These are the new parts to produce, the sizes go from the small junction to the one that weights various kilos, and if you want the order you must be able to produce the whole range, and be ready to start in very short time”
The customer came to us asking indications on the forging technique for this alloy with high copper content, in order to know which press and which energies are necessaries, but also which furnace and which temperature would be necessary.
Our reaction was making available what we always have in our company, since we are always ready for these eventualities: hot forging presses, induction and gas heating furnaces, and obviously all the collaboration of our staff. We immediately organized some forging tests and realized first samples of the parts: thanks to Calipso system for process data collecting and analysis, our customer could understand which forces and temperatures are needed for forging this special copper alloy.
Last minute solution of Mecolpress
All this process has also led to understand that the new press just ordered by our customer would not be suitable for these products, that in order to be efficiently forged, need an accurate check of the material flow in the die.
The solution? Turning the order of an eccentric press at continuous cycle into a hydraulic press of ME series, that thanks to its construction technology and to a sophisticated software, permits a total programming of the forging process.
Moreover, at Mecolpress the hydraulic presses are available with very short delivery time, even starting from 4 weeks for some models. This happens because, with the market experience we have accumulated in years and after many sold presses, we are able to anticipate the customer’s needs and to have quite ready the presses we will sell in the future.
Then, our customer could go back to his German customer and confirm him that just in 3 months from the date of their first meeting, he would be able to satisfy him, with a new forging line, at high technology, dedicated to his product and able to grant the quality of the forged parts.
A won challenge for our customer, and a satisfaction for us for having helped him and to reinforce his imagine of supplier of very high reliability among his customers.
