BEST PERFORMANCE IN GREEN BRASS FORGING: DISCOVER THE INNOVATIVE MECOLPRESS SOLUTION

In recent years, all production sectors have been looking for sustainable and innovative solutions, seeking alternatives with low environmental impact, based on recycling, where possible, with particular attention to the health of all of us.

The international environmental policies are trying to reduce, as much as possible, the presence of potentially toxic materials in products that are on sale and in use.

The aim is to enable a circular economy that allows the recycling of components that have reached the end of their life, preventing them from representing a threat to the environment and health. The regulations launched in the United States and Europe (RoHS, ELV, CSPIA, DWD, ..) have been adopted by most of the world’s states or at least indicated as guidelines to follow.

A relevant part of the forged brass pieces is in contact with water, even drinking water, the presence of lead increases the risk of contamination, the use of lead-free brass alloys therefore limits the health risks.

In the production of brass, the material under investigation is precisely Lead, which has always been used as an alloy element to:

  • improve workability on tool machines;
  • improve the quality of cast products (low porosity);
  • decrease contact friction.

The percentage of lead used in brass alloys goes   from 1.5 to 3.5% and is incompatible with the target of limiting its presence to 0.1% for each homogeneous material.

 

Using lead-free brass alloys

The companies that are involved in hot forging of brass are therefore faced with the challenging choice of using lead-free alloys, but there is no shortage of doubts:

  • What consequences could, this change in chemical composition, have on the production process?
  • Can the current forging capabilities still be considered valid?
  • What updating\improving should be planned in the forging department?

 

Over the past few years, we have worked to find the answers, and based on our experience we can therefore provide some practical adviceto successfully produce lead-free brass forged parts!

Sustainable forging, how to do it?

· Bar cutting

Cutting bars using rotating disc blades is recommended to ensure correct weight accuracy.

Tool steel/high speed steel (HSS) discs are no longer sufficient to guarantee an acceptable service life. It is necessary to switch to discs with tungsten carbide base material inserts (TCT).

Below we propose a balance of the pros/cons for each of your technologies, usually when the production of lead-free brass is around 70-80% total, TCT blades are economically advantageous.

 

HSS BLADE TCT BLADE
Low unit cost High unit cost
Extremely short service life High service life
Re-sharpenable Not re-sharpenable
Reduced blade thickness Reduced blade thickness

 

Oil lubrication of the blade is necessary to reduce frictional heat.

The cutting precision must be extreme to avoid problems during the forging process, especially if it is without burr\flash. The cutting machine and the blade guidance system must have an extremely rigid body. The maximum error allowed is 0.1mm.

It is also suggested an optimization of the cutting process to minimize/eliminate material waste, given the ever-increasing costs.

Modern cutting technologies allow:

  • 5mm head cuts;
  • cutting of the same bar with different lengths to eliminate tail waste;
  • differentiated unloading for the different cuts: head, length A and length B.

 

· Characteristics of lead-free brass

Lead-free brass has physical and mechanical characteristics that are very different from traditional brass.

Standard Brass with Lead Lead Free Brass
Specific Gravity [g/cm3] 8,5 8,3
Thermal Conductivity [W/m] 114 35
Electrical Conductivity [%IACS] 26 8
Coefficient of Thermal Expansion [X10-6/] 21 20
Liquidus Temperature [ ] 900 890
Solidus Temperature [] 885 855
Tensile Strength [Mpa] 435 650
0.2%Yield Strength [Mpa] 295 450
Elongation [%] 25 20
Hardness [HV] 140 200

 

Lead-free brasses are tougher, more resistant and more refractory to heat transmission.

This trend is also confirmed when the heating temperature increases.

ottone senza piombo temperatura di riscaldo

At the same heating temperature:

  • Lead-free brass has a higher resistance to deformation value;
  • Lead-free brass has a higher sensitivity to change in resistance to deformation in case of temperature variation.

Maintaining a heating temperature with the lowest possible variance (+- 5°C) is the key to have a reliable hot forging process.

The mechanical presses of a few decades ago were not designed with safety criteria that are suitable for these materials: simply because these materials did not exist at the time!

· Mechanical presses suitable for stamping lead-free brass

It is therefore essential to choose a press suitable for forging the new types of lead-free brass alloys.

Mecolpress SEO\HEAVY mechanical presses guarantee:

  1. Greater rigidity and safety margin of the structures (+50%) with capacity up to 700t.
  2. Greater safety margin of the transmission systems (up to +50% with epicyclic system).
  3. Hydraulic reaction cushions with increased capacity (+20%).
  4. Hydraulic cushions with SOFT IMPACT or OVERBOOST system to mitigate the impact force or increase the closing forces (+100%), with capacity up to 120ton.
  5. Air\oil lubrication system up to 30 points to lubricate and cool the critical points of the die (integrated\external).
  6. Water cooling of the most critical components.
  7. Hydraulic unlocking in the slide in case of overload to preserve the mechanical components.
  8. CALIPSO control system that memorizes the fundamental parameters for each die cycle to have full control of the process.

 

The ME hydraulic presses by Mecolpress guarantee:

  1. Net die closing force up to 350 tons.
  2. Thrust force of the lateral and vertical punches up to 240 tons.
  3. Maximization of flash-free die.
  4. Punch kinematics system that maximizes force in the final phases of the stroke.
  5. Air/oil lubrication system up to 30 points to lubricate and cool the critical points of the die (integrated/external).
  6. Water cooling of the most critical components.
  7. CALIPSO control system that memorizes the fundamental parameters for each die cycle to have full control of the process.
Pressa idraulica ME350
Pressa Meccanica Heavy 400

Don’t be caught unprepared, current regulations have started to reduce the use of lead and future ones will be even more restrictive, Mecolpress’s hot brass forging technology is ready to go!

Are you interested about forging lead-free brass parts?

Contact us and we will be pleased to support you!

sales@mecolpress.com

Tel. +39 030 25 60 110

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fiera mecspe 2020

Friction Srew Press – MECSPE 2020

Mecolpress will partecipate in MECSPE, at Fiere di Parma from 29 to 31 October 2020.

We exhibit the FPN 220 friction screw press.

For 19 editions MECSPE has been the greatest event focused on innovations for the manufacturing industry.

The numbers of Mecspe:

135.000 SQUARE METERS

56.498 VISITORS

2.306 EXHIBITORS

12 THEMATIC SHOWS:

360° innovation, the fair offers a complete overview of innovative materials, machines and technologies, Industry 4.0.

This event offers an interesting moment of meeting between companies, professionals and associations to build new opportunities for the manufacturing market.

 

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:

    marketing communications

    This ticket will allow you to access the exhibition area, participate in conferences, attend the demonstration areas and special initiatives of Mecspe 2020, and take advantage of free parking.

    You can find us here:

    MECOLPRESS

    Hall 8 Non-ferrous materials and alloys, Stand M24.

     

    For the 2020 edition of MECSPE, Mecolpress exhibits the FPN 220 Friction Screw Press

    The screw presses like the one we bring to MECSPE are used for the hot forging of brass and steel parts, or with any type of material in general.

    They are characterized by the production of solid pieces, or that require multiple forming steps.

    Find out more by consulting the screw presses category on our blog.

    We are therefore waiting for you at MECSPE!

    MECSPE

    Location: Fiere di Parma
    Address: Viale delle Esposizioni, 393A – 43126 PARMA (PR)
    Date: 29 – 31 October 2020 – Thursday, Friday, Saturday

    Opening Hours: 9.00 – 18.00 (Thursday and Friday); 9.00 – 17.30 (Saturday)

    Visitor entrances: Reception Sud, Est, Nord, Ovest
    Visitor Parking: adjacent to the entrances

     

    https://www.mecspe.com/en/

    https://www.mecspe.com/en/magazine/

     

    The excellence of technology applied to industry.

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    Interviews in the company: Riccardo Segreto

    At Mecolpress offices we met Mr. Riccardo Segreto, person in charge of dies test and brass forging department.

     

    What is your role in the company?
    I follow the dies design for the parts forging both in brass and aluminum. Then I follow the starting test for the set-up of the die with all the necessary procedures to prepare it, to make it work properly, also suggesting the proper maintenance.

    From which sector do you come from?
    I have 25 years of experience in the forging sector, during which I mainly took care of brass hot forging process.

    So, we are mostly speaking about brass. There are different types…
    Indeed, the brass is an alloy that can be combined in many different types. Recently the tendency to produce it without lead is affirming. In this Italy follows Germany, where Ecobrass is used for a few years now, that indeed is without lead. Since the brass produced parts are largely directed to the domestic water circuits and installation, it is clear that the presence of lead represents a danger.

    In the sector of taps and fittings, components, the same norms forbid the lead usage.

    This is good for our health but taking off the lead from the brass alloy means to reduce its processability and this reflects on the machines, because the traditional ones are no more adequate, for example due to high cycle times or uncontrollable vibrations during the working phase.

    Critical issues that arrive then to the machines. What is the answer from Mecolpress?

    The company philosophy is focused on the absolute quality. Translated into concrete terms, regarding brass it means to be able to forge without flash. In this case, our hydraulic presses are very efficient. These are machines that guarantee a drastic reduction of wastes and an optimum quality of parts.

    Do you speak about all parts, without differences?

    Yes, the range of productions is very wide, from the ball valves to the T junctions, from components for gas plants to automotive parts. The choice is complete.

    Which features contribute to the good functioning of the machine?
    Reaffirming that when there is no flash some problems can be considered as to be solved, I would mention the simulation program that is a valid help for the forging of very particular parts. It is a software that, once the parametrization is given by the Mecolpress designers, shows the material flow inside the die, allowing to prevent deformation flaws in the points of impact or the brusque alterations of temperature that generate criticalities in the parts. Even if it does not replace the sensitivity of an artisan, and his experience can indicate reliably the points that need adjustments and corrections. And it allows – this is the advantage – to intervene in time.

    The message of Mecolpress is above all a call to quality. How do the customers react?
    Many operators of our sector are at this point convinced that our advantage incentive is the quality. They understand that to stay active on the international market, they need to be protected, and not to give up with the features for which the Italian companies are always very appreciated worldwide. It is not convenient to lose time in the battles on new orders fighting on few euros, according to us it is always better to offer a 100% quality standard. This is the distinctive characteristic of our presses and the factor that brings more satisfactions.

    I mention gladly the last one: we are working hard on a test of 100.000 parts (brass sanitary taps and fittings), commissioned by a German producer that turned to us after he asked to competitors. They request to forge 100.000 parts without flash and without changing the die: we took up the challenge, but we are sure that we will win the challenge.

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