If the forging industrial process is stable and steady, it generates profit!
If the forging industrial process is stable and steady, it generates profit!
Today more than ever it is very important that the industrial process, in our case the hot forging one, remains stable and steady during operations time. As a matter of fact, by achieving this goal it is possible to generate profit.
The costs increase in raw materials, energy and specialized personnel is a more and more important and relevant constant for every manufacturing business. The profit of each order or job must always deal with these variables which can hardly be controlled.
The production stability can be controlled: the process must always be repeatable in the performances and must grant steady operative costs.
The metals hot forging is not an exception. Annual productions can reach tens of millions of pieces and each of these must be produced following the expected and planned parameters, the profit expectation must be guaranteed!
How is it possible to manage, monitor and correct tens of parameters, for millions of parts, granting the stability?
It is possible to grant the process stability even when millions of parts are produced and the process parameters are numerous, in this way:
01
=> monitoring the variability factors that influence each process to understand if they are under control or not by means of the statistical control.
02
=> Obtaining highest rigidities, forging force, and positioning precision.
03
=> Real time check of the behaviour of the main process parameters.
04
=> Modification of the main forging values without interrupting the production.
Statistics teaches that Cp and Cpk parameters are fundamental for controlling the progress of the forging process, for each variable in fact they are the key to understand its stability.
The example of the shooting with darts game allows you to quickly understand the concept:
a good Cp indicates that we are very repeatable in our shots, but it does not mean that we are hitting the target.
Only by obtaining a good Cpk, too, as a matter of fact, the optimal result is guaranteed!
=> Cp e Cpk must be much higher than one.
Let’s move on to a practical forging example:
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Forging a batch of 25,000 water meters.
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or forging a batch of 50,000 gas control valves
The dimensions of the forged parts are determined:
- by the surfaces of the part shape created in the die.
Cp depends on the presses rigidity performance and on the die design.
Cpk depends on the correct evaluation of the material shrinkage, which is related to the forging temperatures, to the part geometry and raw material chemical composition.
- by the punches involved in the material deformation.
Cp is obtained from punches rigidity and thrust force.
Cpk is obtained from the possibility to adjust the punch arrival position.
During the forging tests carried out with our customers from all over the world, the dimensional statistical analyses carried out on the produced samples (batches of thousands of pieces) have demonstrated that Cp and Cpk parameters were always abundantly and stably higher than one.
The complex geometries or the parts dimensions are not a problem.
How could we maintain the forging industrial process stable on our ME Hydraulic Presses?
- Mecolpress presses are equipped with Calipso software for operative parameters setting and their continuous control. Calipso, software entirely developed by Mecolpress, allows you to control the main process parameters in real time (forging forces, position, speed, …). Even before measuring the pieces, it is possible to understand if the forging process is stable and guarantees constant performance.
- Our presses are designed with advanced calculation systems (FEM) which allow to predict the rigidity of the components with the utmost precision, minimizing their deformations, even if subjected to high loads.
=> Cp under control
- We have designed our hot forging presses in order to have the highest possible dies closing force and maximum punch thrust force.
=> Cp under control
- The stroke adjustment of the individual punches occurs in real time, thus allowing the related dimensions to be modified during production.
=> Cp under control
- The long experience in dies design and the collaboration with the best specialized companies in the sector have allowed us to create the dies with extreme accuracy, in order to guarantee stable production of the pieces.
=> Cp under control
ME 350 NEXT GENERATION PRESS
ME 350 Next Generation Press: still the most powerful press, now it also minimizes the energy consumption.
ME350 press is the powerful of Mecolpress hydraulic presses: the latest version we have developed is able to grant a significant reduction in energy consumption.
Our goal is to make our customers more competitive in a very challenging market. The increase in the costs of raw materials and energy is not yet stabilized and a substantial reduction is not yet in sight. Our customers have to manage and deal with variables such as:
- product differentiation,
- the need to adapt to high volume production batches,
- managing frequent product changes,
- the difficulty of finding a stable workforce,
- the need to produce just in time,
- the increasingly high quality required of the forged product.
Mecolpress technological innovation starts from the challenges the market imposes on producers with the aim of overcoming them.
The new ME350 Next Generation press incorporates all the latest innovations:
01
Maximum dies closing force and maximum one of the independent extruder punches => flash-free forging and reduced thicknesses => reduction in raw material consumption (up to 40% compared to traditional forging).
02
Regenerative hydraulic circuit and adaptive power control to harmonize the energy consumption with the effective forging demand => reduction of electricity consumption (up to 50% compared to the presses of previous generation).
03
Anthropomorphic loading robot and quick dies changing system => increased flexibility by changing a product with another, reducing the necessary machine downtime.
04
Possibility of forging more parts each cycle in the shortest time, reaching the production of 5,000 pieces per hour => high-volume production batches are completed in a short time.
05
The production process is fully automated and connected to existing MES\ERP systems (Industry 4.0) => better staff management who can easily manage multiple presses simultaneously without stress.
06
CALIPSO Software checks the trend of the forging parameters (forces, displacements, sequences, ..) by comparing them with the references => any possible criticality on the quality of the product is overlined in real time and the part is separated from the correct ones.
All these innovations are added to Mecolpress long-lasting experience in the forging field, gained in the province of Brescia, a key area in the global panorama of the production of brass components. Mecolpress offers to the customers a vast availability of spare parts to minimize the relative delivery times and a team of specialized technicians to carry out assistance interventions all over the world.
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:
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: