Differentiated unloading of the forged pieces
The press automatically separates the forged parts and divide them into different boxes. The press has become intelligent!
The differentiated unloading of the forged parts is an interesting function that Mecolpress provides by default on all hydraulic presses, but it can also be added as an option on eccentric mechanical presses.
Hot forging for higher quality of forged parts
The metal hot forging differs from the cold one because it allows you to obtain high quality pieces through an important deformation of the starting material. By working brass, copper, titanium, steel and aluminium by means of hot forging presses, in fact, it is possible to produce particular shapes, even with complex geometries.
The metal hot forging therefore allows to obtain parts that are more resistant than those obtained through other production processes.
In particular, metal hot forging can increase the strength and resistance of the products. For these reasons, the production of hot forged pieces guarantees specific advantages in their mechanical characteristics compared to those produced with other technologies such as casting or mechanical machining with chip removal.
The hot forging, compared to the casting processes, allows to obtain mechanical characteristics and surface appearance of superior quality. We at Mecolpress know it well, so much that we have made “Technology of Shape” our motto.
The piece produced must therefore be perfect, its quality must be certified. For this reason, Mecolpress has designed a system that allows the press automatically separates the perfect forged parts from those to be evaluated as they may not be such.
Why is it so important that the press separates the perfect forged parts from those to be evaluated?
From the automotive sector, the Lean production method teach us:
- Companies 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.
- 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.
One of the most recurring needs in our customers is to have an ever more intense control of the forging process: the machine must be able to control as many parameters as possible important for the forging process, record them to make statistical predictions on the deviation from the optimal production, carry out checks.
Mecolpress offers a series of forging presses that fully meet the needs described above: the ME hydraulic series.
The hydraulic presses can control numerous process parameters and on these manage the logic for rejects or collect the measured values for statistical analysis. For example, they can control:
- the temperature of the billets to be loaded,
- the coring punches penetration time,
- the punches real penetration force,
- the final position reached by each punch.
Here you can learn more about the most important process parameters that hydraulic presses are able to evaluate.
The machines of the ME series have the credentials to be competitive in a modern and controlled forging field; they operate at their best on medium / small batches, thanks to their flexibility.
In this video we show how our hydraulic presses perform the differentiated unloading of the forged parts:
The pieces that do not fully comply with the process parameters set by the operator and analysed by our powerful Calipso software to control the forging process, are unloaded in a separate bin.
For the customer this operation translates into an important saving method:
- Less waste of time,
- Less material / pieces to be discarded,
- Be sure that the forged piece complies with the required characteristics,
- Get perfect shapes.
With regularity and continuity, Mecolpress gains new Italian customers, the hydraulic press is confirming to be the winning choice.
Case Study: How we acquired the latest customer from Brescia
We report the case of a new customer based in Brescia that we have just acquired, an interesting case study to understand which are the necessities of the companies working in the hot forging sector and how Mecolpress provides answers.
It is the case of a company established in the international market for the very high quality of its production, consisting mainly of mini valves, valves and fittings for the sanitary and heating sector. This company has its own brass hot forging department, developed to cover the 100% of the forged parts needs; the recourse to very few and highly selected external suppliers happens just in case of particular peak of volumes.
The presses equipment of this company consists of 5 machines, always full of work: 3 more traditional and “dated” (eccentric mechanical presses of the historic producer Rovetta, that now no longer exists) and two more recent little hydraulic presses of a particular type, proposed by an European producer.
Knowing better the company, now customer of us, we could appreciate right from the beginning some undisputed features:
- Advanced transfer machines;
- A working method focused on the precise and deep knowledge of all the productive processes;
- A forward-looking vision on the continuous training of all the personnel that is involved with the management regarding the strategic decisions and that creates a uniform a close-knit group;
- A quality department having knowledge, methodologies and instruments not only for the examination of the parts but also for the evaluation of the method used for their production.
During various meeting both at customer’s and Mecolpress site, we had the opportunity to present them our complete range of presses and in particular the functionalities of our hydraulic presses of ME series.
The customer wanted to test us, taking advantage of the Mecolpress strategy of having a selection of presses almost ready for delivery, for carrying out forging simulations with two parts of their production range on the specific press of their interest.
The result was that, thanks to the constructive collaboration of both teams (the customer and the Mecolpress ones), in just 9 weeks from the decision of beginning with the simulations, we could:
- Carry out the forging simulations of the two parts to be tested;
- Manufacture the related forging dies;
- Carry out forging tests with two dies (in manual and in automatic cycle, since Mecolpress has 2 high-performing push-type gas furnaces;
- Dismantle and demolish one of the old presses of the Customer;
- Deliver at customer site in Brescia a new ME150/4G62 hydraulic press, exactly the same one the customer saw and tried.
Why the company under consideration chose Mecolpress?
We thank the customer for the trust and for having tested us, and we are particularly proud that even they, as other customers, after having bought and used the hydraulic presses of our competitors, have chosen to purchase Mecolpress for the future.
The decisive points for this new positive result are in short:
- Mecolpress can offer to the customer not only any kind of new presses, but also exceptional expertise in the maintenance of old presses, of other manufacturers (in this case Rovetta).
- Mecolpress hydraulic presses, both for mechanical and construction project and for extremely developed software, offer to the user an incomparable ease and usage flexibility.
- Choosing Mecolpress, the possibility to conclude an investment in very short time, and to see it becoming rapidly productive; who wants to invest has no time to wait and must be helped to be competitive as soon as possible!
Forge up to 60 pieces per minute without flash!
Our range of hot forging hydraulic presses ME has been enriched with the latest model ME100. It is a compact machine, dedicated to the forging of low-weight complex pieces, with extremely high productivity.
Mecolpress patented hydraulic presses, suitable for hot forging of standard and special brass or aluminium pieces.
This clamping force is higher than those of traditional mechanical presses. Independent & controlled movements of the ram and punches allow for flash-less hot forging also of complex pieces.
In addition to the ME150, ME250, ME350, we now also offer the ME100:
- 100 Tons of die closing force;
- 30 Tons for each of the punches (there can be up to 5)
- Forge in single or double figure, horizontally or vertically, and it is Super-Fast!
We tested it up to 30 strokes per minute and of course … it was promoted with full score!
As for all our ME hydraulic presses, the range of pieces that can be forged is very wide.
Here is a photo of typical brass parts that can be forged with this press:
Some info as an example:
– it can print ball valve bodies up to 3/4 inch, without flash (in single figure), or 1/2 inch in double figure.
– Accepts dies size 180x180mm.
– Punches stroke: 75mm.
Mecolpress has in fact the skills and the appropriate structure to make you ad hoc consultancy. Through the drawing of the piece you want to forge, we can perform a die simulation through the dedicated software in our internal technical office.
It will also be possible, if necessary, to carry out a real forging test of your piece thanks to the machines that we always have available at our company to carry out forging tests. We are thus able to offer you the machine, or the most suitable forging line for your needs.
And if the right press for you was not the ME100, we are always able to make the specific proposal for the needs of each customer, because Mecolpress has the widest range of hot forging presses of all!
In this video you can see the hot forging of gate valves with a ME hydraulic press.
Go beyond the normal criticality of the forging of these valves, get a piece without flash and reduce production costs.
What are gate valves and how they are traditionally forged?
The brass or other materials gate valves have the function of fluid flow adjusting and stopping onto a tube. They fulfil this control through a hand wheel (or a motorized actuator).
To give you an idea, you can compare the function of the mentioned valve to the closing of a gate slide in the middle of a tunnel flooded by the water.
Usually the gate valves are hot forged through traditional eccentric mechanical presses, but their realization is not easy, above all if you want to forge the part without possible defects, using little material (therefore with the most possible depth of all the holes) or without flash as well.
The traditional forging of gate valves by means of eccentric mechanical presses requires a greater energy compared to the one necessary for forging of ball valves having the same dimensions, and it requires a much higher punches stroke, in particular for one of them.
For example, for the realization of gate valves of 2 inches or more, eccentric mechanical presses of minimum 450 tons capacity and a forging tool (defined as bell tool) that allows the realization of holes of great diameter are normally used.
This technology has been valid and successfully used for many years, and Mecolpress as well proposes it to its customers through its SEO and SEO CVE CS presses series.
Gate valves forged by means of hydraulic presses
There is also a much more efficient way for gate valves hot forging: ME hydraulic press.
ME hydraulic presses, in fact, thanks to the different working dynamics of the punches, are proving to be really decisive for all the forgings of more “problematic” and complex parts, consenting for example to avoid the use of EV bell tool.
As we show in this video by means of ME presses you can forge high quality gate valves, without flash, detail of great importance. The presence of flash in the forged parts implicates a considerable waste of material, and moreover, to remove it, it is necessary to use a trimming press, which means therefore that you will have to equip yourself with an additional machine.
Another interesting aspect to be underlined is the fact that hydraulic presses have a cycle frequency significantly higher than normal mechanical presses.
Our ME hydraulic presses have also as standard equipment the Calipso software, our innovative program for collecting and checking forging data. Through this intelligent system you can perform analyses of the production process, but not only! In fact, it is possible to obtain an optimal and separate management of any pieces to be discarded or otherwise to be evaluated.
The checking of the pieces carried out by Calipso guarantees the certified quality of each piece produced.
Another important advantage that is standard on our ME hydraulic presses is the innovative die lubrication system, that can also be optionally applied to eccentric continuous cycle presses. In hot forging it is important not to underestimate the way in which the dies are lubricated; finding the “perfect” lubrication in your forging process ensures an increase in the life of the dies and materials unattainable with traditional systems!
The ME hydraulic press has an innovative forging system compared to traditional mechanical presses. Innovative because, for example, it does not generate mechanical shocks, it considerably reduces the noise generated during production, the tooling is much faster and more convenient.
Here is the video of the forged gate valves with ME hydraulic press:
The advantages of using hydraulic presses in gate valves hot forging
In summary, why should you choose a hydraulic press to forge gate valves?
- No bell EV tool,
- Gate valve without flash,
- Forged pieces controlled by the powerful Calipso software,
- Separate management of non-compliant parts,
- Better forging lubrication system,
- No mechanical shock,
- Less noise,
- More setup speed.
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.
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.
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.
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.
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.
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.
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.
- 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.
– 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.
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”.