baixie plc forging hammer and its forming technique of multi pieces forged by one-mould
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If you are interesting in this, or have some probleme, please let me know!Jagen Zhong Haian Baixie Forging Hammer Co.,Ltd.Add: No. 6 Yangmanhe Industrial Park, Haian, Jiangsu Province, China ZIP Code: 226600Tel/ Fax: 0086-513-8889 1498 Mob:0086(0)159 9659 3080http://www.forging-hammer.com/Email:[email protected] ; [email protected]:[email protected] Skype:forginghammerhttp://cn.linkedin.com/in/forginghammerTRANSCRIPT
Baixie PLC Forging Hammer and its Forming Technique of multi-pieces forged by one-mould
Abstract: Cost curbing and efficiency improvement is the eternal theme of technical improvement of forging
enterprises. Baixie always regards “providing service for the industry and creating values for our guests” as the
significant task. Year after year, we make progress and grow shoulder to shoulder with our guests. We have
accumulated abundant practical and theoretical experience and have achieved a lot through the application of PLC
forging hammers and one mould several parts forming technique, through cutting production process, reducing
resources consumption, improving working condition, raising production efficiency, up-grading forgings’ quality
and so on.
Key words: PLC forging hammer; one mould several parts; flexibility; multi-impression die
1 The Technique Advantages of One Mould
with multi-cavities. Several Parts Forming
Reducing cost and raising efficiency is the eternal
theme of technical improvement of forging enterprises.
With the technical advancement of mould
manufacturing equipment, the manufacturing accuracy
of multi-cavity mould is guaranteed and one mould
several parts forming technique is gradually
popularized and applied.
One mould several parts forming means several
parts forming with one mould through reasonable
cavity arrangement on the same mould with proper
forming sequence.
Advantages of One Mould Several Parts Forming:
Improve production efficiency several times over.
With same labor and same production sequence, one
mould several parts forming can make better output.
Shorten production process. Through reasonable
cavity arrangement, parallel or interlock, regarding
several parts as a whole to measure boundary section,
which reduces the difference of cross section and
keeps metal materials layout even, thus make the best
use of raw materials and realize the purposes of
facilitating metal forming process and cutting down
the technique process.
Reduce mould consumption. One mould several
parts forming greatly 1reduces single part’s cost;
multi-cavity forging is adopted to realize forgings
forming and accuracy through pre-forging and
end-forging cavity, which improve moulds’ working
life several times over. The forgings’ surface quality
and accuracy are also improved. As to some forgings
of great drop height, parallel layout can kill offset
power from producing single part to improve moulds’
working life.
Improve materials utilization. One mould several
parts forming with proper arrangement can improve
materials’ utilization through reducing cross section
difference, sharing overlap, lessening jaw material and
other measures.
Improve machine’s utilization. One mould several
parts forming uses only one forging hammer to
complete several technique processes, thus improve
machine especially the cutting machine’s utilization.
Reduce resources consumption. Cutting technique
process, enhancing production efficiency, and
improving machine and material utilization all
contribute to resources consumption reduction.
2 Technique Requirements of One Mould
Several Parts Forming and Mould Design
One mould several parts forming should be reasonably
arranged according to forging’s shape to choose one
mould two parts, one mould three parts or more. The
layout of the work pieces can be opposite vertex,
interlock, parallel or many other
forms.
Opposite vertex layout
Interlock layout
Parallel layout
At the same time, such factors as shortening
technique process, improving material utilization,
simplifying forming process, expanding mould life,
up-grading mould quality, convenient to operate and
easy to form and other factors should be taken into
overall consideration.
One mould several parts forming usually adopts
single heat through multi-cavity,
multi-technique-process. Some use professional
machine such as roll forging and cross wedge rolling
to blank, and distribute blank with roughly the same
volume of forgings through raw materials reallocation
and then through bend hitting, pre-forging,
end-forging to accomplish forming.
One mould several parts forming, cavity needs to
analyze forging’s shape to choose proper layout forms;
if condition permitted, choose as shallow point of
groove as possible at the boundary of cavities to avoid
forging deformation when forming, so as to reduce
gap, that is to say to save material and reduce forming
strength. Groove gap, which is usually half to one
time of groove depth, should be determined by the
difficulty of forging forming. The easier the forming is,
the smaller the gap should be.
When choose one mould several parts forming,
high-accuracy forging processing equipment (e.g.
CNC milling) should be equipped to guarantee
position accuracy between forging grooves.
In one mould several parts forming, the gap
between two grooves is relatively small, if side-cutted
all parts at the same time, it would be very difficult
because the rigidity of cavity plate is relatively weak.
So, side cutting for one part each time is usually
adopted. When design cavity plate, attention should be
paid to demise, or it would cause damage to work
pieces.
One mould two parts three-mode cavity forging
One mould two parts connecting rod two-mode cavity forging
3 Performance Advantage and Application
in One Mould Several Parts Forming of
PLC Forging Hammer
It is well-known that forging hammer is a kind of
forming equipment with simplest structure, best
adaptability, and moderate purchasing cost. Its greatest
advantage in forging’s forming process lies in its fast
forming speed, high hitting frequency, and ability to
withstand partial strike. High efficiency, flexibility,
and fast speed are the main technique features for
forging hammers being widely used.
Baixie PLC Forging Hammers’ Performance
Advantages:
High efficiency
The ram can obtain
huge energy to
realize continuous
forging with high
speed and frequency
due to fully
hydraulic driving
system.
Energy-saving
Driven by
fully-hydraulic
driving system, driving efficiency can reach 65%, thus
greatly improve energy utilization.
Environmental friendly Auto-control of striking
energy avoids the noise problem caused by surplus
striking energy. Spring, damping isolator and
counterblow structure with same striking energy can
sufficiently reduce striking vibration by absorbing
about 85% striking vibration. Fully-hydraulic driving
system discharges no waste emission.
High accuracy U-shape casting steel frame, easily
dismounting wide guides as well as good die
alignment and adjustment structure realize the
programming control system of striking energy,
guarantee forgings forming with high accuracy and
the realize the eccentric blow of forging hammer.
High reliability Highly integrated hydraulic driving
technology greatly simplify the system structure and
guarantee the reliability of the equipment.
Automation Intelligence programming control
system is adopted to ensure the accuracy of striking
energy. Besides, striking energy and frequency can be
adjusted through PLC system to meet different work
pieces’ forging technique. Operating terminals all
instructed in Chinese, which lower the requirement to
operators; unmanned operation can be realized
through interaction with robots. Forging hammer is
the core equipment in the forging production line. Its
automation determines the automation of the whole
production line.
Baixie PLC forging hammer, which meets
environmental protection requirements, has become a
modern green forging equipment in forging industry
with such features as high efficiency, energy saving,
environment friendly, high accuracy, and high
reliability.
4 The adaptability of Baixie PLC
Forging Hammer in One Mould Several
Parts Forming
One mould several parts forming increases
difficulty in parts forging forming. Multi-cavity
forging such as blanking, bending, pre-forging and
end-forging cavity is usually used to improve material
utilization and ensure good filling ability.
One mould several parts forming asks forming
equipments for higher flexibility and resisting
deflecting load ability.
Forging hammer is the equipment can truly strike
while the iron is hot. It is especially suitable for the
forging of multi-cavity, one mould several parts
forming, irregular-shaped parts, thin ribs and the
forging of parts with weight tolerance requirements.
Shanghai Surgical Instruments Group’s one mould two parts
forging production line
Forging hammer’s features of flexibility and
adaptability to multi-impression die forging are
exactly the requirement of one mould several parts
forming. Multi-impression die forging of the forging
hammer can get the most reasonable material
distribution, which avoids the defects such as single
groove, great deformation of blank center after one
strike, large overlap caused by intense horizontal flow,
and the metal’s being not easily filled deep in groove.
Multi-impression die forging can also thoroughly
break oxide cover, thus improve product’s surface
quality.
Hardware one mould two parts forming production line(10 lines of
Maxpower Tool Group)
Baixie’s PLC forging hammer, as the model of
modern forging hammer, its fast and flexibility have
been given full play while its defects have been
overcome by modern hydraulic driving, electronic
control and structural optimization.
5 Application of Baixie PLC Forging
Hammer in One Mould Several Parts
Forming
5.1 One Mould Six Parts Hot Forging Die of
Cross –axis
Air hammer is used in traditional process to
blank and then press a single piece each time by
friction pressing machine, which has been replaced by
PLC fully-hydraulic die forging technique. Because of
die forging hammer’s high striking frequency, striking
energy and its process sequence of each blow being
set by program, so the productivity of a single
production line with one person equals to the original
6 lines with 24 people. The application of one mould
six parts forging technique not only greatly improve
working efficiency but also save the materials. In one
mould six parts forging, every two parts share one
overlap, so the overlap quantity of 6 parts is equal to
the original 4 parts.
Table 1 a comparison between traditional and modern
technique of cross-axis
c o n t e n t
Friction press
single cavity
forging production
line
PLC One mould
several parts
forming production
line
Cross-axis
forming
technique
Heating(single)-air
hammer produce
blank-friction press
machine forming at
one time -
Trimming
Heating (one mould 6
parts)-PLC forging
hammer two-mode
boring three-position
five hammer forging-
Trimming
n o . o f
production
s t a f f
4 3
Output per
capita 1 6~8
s i t e a r e a
r a t i o 6 1
E n e r g y
consumption 3 1
Mould life 1 3
M a t e r i a l
u t i l izat ion 80% 89%
5.2 One Mould Two Parts Forging Die of
Connecting Rod
Connecting rod is an important part in engine for
torque transmission. Connecting rod should be of
good mechanical properties, high machining accuracy
and weight accuracy to endure alternating stress in
high speed movement. Recently, the relatively
advanced connecting rod precise forging production
lines are as follows:
The forming technique process of PLC forging
hammer centered production line: induction heating-
die forging on hammer(one mould two parts two-mode
boring four hammer forging) – Trimming
Table 2 a comparison between traditional and modern
technique of connecting rod
c o n t e n t
Friction press
single cavity
forging
production line
PLC One mould two
parts forming
production line
Connecting
rod forming
technique
Heating-air
hammer produce
blank-friction
press machine
forming at one
time - trimming
heating- PLC die
forging hammer one
mould two parts
two-mode boring four
hammer forging–
trimming
N O . o f
production
s t a f f
5 2~3
Productivity
per capita 1 3
Mould life 1 Over 3
5.3 Wrench Body One Mould Two Parts Forging
The traditional technique uses air hammer to blank,
pressing machine to bend, and friction pressing
machine with one cavity to form. Due to large
deviation in blanking and low productivity, air
hummer nowadays is replaced by Baixie PLC forging
hammer one mould two parts staggered forming
technique, which not only simplify the process,
improve production efficiency, enhance the
productivity and quality. There is a detailed
comparison as follows:
Table 2 a comparison between traditional and modern
technique of wrench
c o n t e n t
Friction press
single cavity
forging
PLC One mould
two parts forming
production line
production line
Wrench
forming
technique
Heating-air
hammer produce
blank-friction press
machine forming at
one time -
trimming
heating- PLC die
forging hammer one
mould two parts
three-mode boring
four hammer
forging– trimming
N O . o f
production
s t a f f
5 2~3
Productivity
per capita 1 3~4
Mould life 1 Over 3
5.4 Pipe Fittings One Mould Three Parts
Forging Technique
Traditional forging technique: bending with
pressing machine after heating, forming with
one-cavity friction pressing machine and trimming.
Baixie PLC forging hammer one mould two parts
cuts the bending procedure and form exactly after
heating. There is a detailed comparison as follows:
Table 4 a comparison between traditional and modern
technique of pipe fittings
c o n t e n t
Heating-air
hammer produce
blank-friction press
machine forming at
one time - trimming
heating- PLC die
forging hammer one
mould two parts
three-mode boring four
hammer forging–
trimming
Pipe
fitting
forming
technique
heating-bending
with pressing
machine-friction
press machine
heating- PLC die
forging hammer one
mould three parts
two-mode boring three
forming at one time
- trimming
hammer forging–
trimming
N O . o f
production
s t a f f
5 2~3
Productivit
y p e r
c a p i t a
1 4~5
Mould life 1 Over 3
5.5 One Mould Eight Parts Forging Technique of
Rocker
Traditional forging technique: bending with
pressing machine after heating, forming with
one-cavity friction pressing machine and trimming.
One mould eight parts cuts the air hammer blanking
procedure and form exactly after heating. There is a
detailed comparison as follows:
Table 5 a comparison between traditional and modern
technique of rockers
c o n t e n t
Heating-air
hammer
blanking-friction
press machine
forming at one time
- trimming
heating- PLC die
forging hammer one
mould eight parts
two-mode boring three
hammer forging–
trimming
Pipe
fitting
forming
technique
heating-bending
with pressing
machine-friction
press machine
forming at one time
- trimming
heating- PLC die
forging hammer one
mould three parts
two-mode boring three
hammer forging–
trimming
N O . o f
production
s t a f f
5 2~3
Productivit
y p e r
c a p i t a
1 4~5
Mould life 1 Over 3
6 Closing
Baixie regards “providing service for the industry
and creating values for our guests” as the significant
task. Year after year, we make progress and grow
shoulder to shoulder with our guests. Together with
our guests, we will continue to achieve the purpose of
lowering cost and improving production efficiency
through the application of PLC forging hammers and
one mould several parts technique.
Jagen Zhong
Haian Baixie Forging Hammer Co.,Ltd.
Add: No. 6 Yangmanhe Industrial Park, Haian,
Jiangsu Province, China
ZIP Code: 226600
Tel/ Fax: 0086-513-8889 1498
Mob:0086(0)159 9659 3080
http://www.forging-hammer.com/
Email:[email protected] ;
Skype:forginghammer
http://cn.linkedin.com/in/forginghammer