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:jagen.zhong@baixie.com ;

habxzjg@gmail.com

MSN:forginghammer2010@hotmail.com

Skype:forginghammer

http://cn.linkedin.com/in/forginghammer