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.
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:
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”.
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.
Hydraulic Presses Mecolpress
Hydraulic presses are, by their nature, slightly slower than mechanical units of equal strength but have been designed to reduce batch change time. In particular, the system is equipped with the following features:
- Detection of the piece unloaded by means of piece weighing: a sensitive cell housed on the unloading arm weighs the molded pieces and discriminates if the ejection operation has been successful. The system is simple, robust and allows to set the correct weight value for each piece according to the recipe. No adjustments or cleaning is necessary for photosensitive elements.
- Automatic adjustment of the penetration depth punches also during forging: changing the drilling depth is not a problem, a hydraulic system controlled by an encoder allows the centesimal adjustment of the position of the punches.
- Change dies and punches in a single automatic package: the fixed drilling tool makes it possible to change die and punches in a single operation, the machine automatically cuts the dies and inserts the pins.
- Heating of mdies and external punches in shade with respect to the production: being able to change dies and punches in automatic allows to heat them during the forging operations carried out by means of hydraulic presses, that is in shade with respect to production time. This feature saves more than half an hour for each die change.
- Adjustment of the pressing force of each press and of each individual punch: the press and each individual punch have adjustable forces and speeds within wide margins, this allows to find the correct motion law for each material and for each die.
- Detection of the force exerted by each individual punch for pin damage detection: load cells in the pins provide for the detection of the real force exerted by the punch. This makes it possible to detect piece scraps due, for example, to the punch break, or allows adjustment of the punch energy in order to minimize machine consumption.
