Press Design for the 21st Century - Part 2 Click for Part 1 ...

• Press Design Elements
• "Pull Down" type Press
• "Push Down" type Press
• Press Structural Features
• Forging Manipulators
• Auxilliary Equipment
• Sinusoidal Drive System
• Programmed Forging

FORGING MANIPULATORS

As the forging press is upgraded in speed and operational precision, a forging manipulator becomes necessary which can faithfully follow the press motions in speed and precision for the whole press installation to be successful.

Wepuko Pahnke's forging manipulators incorporate many design features to fully meet this requirement, including the following:

• A vertical recoil system which compensates for the downward movement of the manipulator peel shaft during forging.
• A horizontal damping/recoil system, which feeds the ingot into the forging press on a complete follow up principle during high speed forging operation.
• An automatic rotary correction system, which prevents distortion of the billet/forging.
• Individual pumps for different parts of the system to enable particular manipulating motions to be performed accurately.
• Twin manipulator operation integrated with the press
• One man control of the press manipulator integrated operations.

WPE's forging manipulators are designed with many more functional advantages. Used in combination with high speed forging presses, the manipulator has greatly contributed to achieving high product quality and productivity much to the satisfaction of our customers.

AUXILIARY EQUIPMENT

We are constantly looking to automate our forging press and manipulator systems for higher productivity and greater labor savings.

Consequently, not only the press and manipulator have to be capable of high speed operation, but also the auxiliary equipment around the press. These components have to have excellent design and function to effectively serve the press and manipulator in a total and well balanced manner.

Our many years of experience as a forging press manufacturer enable us to be able to offer a range of auxiliary equipment :

• Elevator Type Turntable - Located between the forging press and manipulator, this turntable is used for turning the ingot as well as for assisting the manipulator in re-gripping the ingot. The turntable is kept at or below floor level during the forging operation.
• Ingot Car - The ingot car is used to transport the ingot to the manipulator and has a rotating top section.
• Automatic Die Change System WPE's forging press systems can incorporate a table shifting device, a bottom die shifting device, die magazine and top die rotating device to shorten the setup time as well as to ensure work safety. All of these die exchange devices can be placed in and out of automatic operation directly from the control desk, and also their operations can be programmed into the computer controlled forging process.

MODIFIED SINUSOIDAL PRESS DRIVE SYSTEM

The sinusoidal press drive system takes full advantage of the variable discharge and reversible discharge direction characteristics of the radial piston pump.

It differs from conventional press drive systems where valves are used to control the press operation and replaces it with a system in which the press operating speed and direction is controlled by changing the direction and rate of pump discharge.

The changeover between the compression downstroke and the decompression upstroke is made by the pump itself.

Advantages

1) The switch between the press downstroke (compression) and upstroke (decompression) is performed at the point of zero pump discharge, eliminating otherwise attendant switching shock. Consequently, vibration and pulsing of associated piping, normally experienced during hydraulic pressure shocks, is almost completely eliminated.

2) The press motion in terms of the operating curve is now simplified, making high speed forging possible.

3) The press motion and speed are directly and accurately proportional to the pump discharge rate, ensuring a high level of pump response. Also, the accuracy of position control is sharply improved (? 0.04? in terms of product accuracy).

4) Since the pump discharge is variable, employing several pumps in proper combination enables the sinusoidal operating curve to be altered or modified as desired. It therefore is feasible to obtain the correct press motion curves most suited to the customer?s forging operations.

5) Energy consumption is up tp 30% less than with conventional press hydraulic drive systems.

Sinusoidal Press Motion :

Conventional Press Motion :

PROGRAMMED FORGING AND INNOVATIVE SOFTWARE

Wepuko Pahnke's programmed forging system thoroughly automates the entire forging operation, including press and manipulator control as well as automatic die change. Additionally, Wepuko Pahnke's FORGEMASTER software is a state-of-the-art, Windows compatible tool to develop pass schedules for bar forging.

The forging programs cover not only relatively simple round or square shaft forging but other complex shaped forgings as well.

Sample Screen of WPE Forging Controls User Interface

Forging for the 21st Century part 1.

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