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Machines for solid metal forming Die Forging Hammers

Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

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Page 1: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Machines for solid metal forming Die Forging Hammers

Page 2: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine
Page 3: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

HO series

Technical data

Schematic of HO-U hammer.

All data are proposals and can be adjusted to customer’s requirements.

A = Max. ram strokeB = Ram depthC = Max. die height without dovetailsD = Min. die height without dovetailsE = Daylight between guidesF = Height above floor

HO series 500 630 800 1000 1250

Blow energy [ kJ ] 50 63 80 100 125

Max. ram stroke [ mm ] 730 760 810 850 1000Ram depth [ mm ] 690 750 800 900 1000

Min. die height without dovetails [ mm ] 220 220 280 300 500(upper and lower die)

Frame base width [ mm ] 2800 3000 3390 3440 4100

Overall weight [ t ] 78 98,5 118 164 213* *with base plate

Blow frequency [ 1/min ] 90 85 80 80 75at nominal working capacity

Max. die height without dovetails [ mm ] 450 460 530 550 730(upper and lower die)

Daylight between guides [ mm ] 700 800 850 850 1000

Frame base depth [ mm ] 1600 2000 2450 2450 3100

Height above floor at a height of floor [ mm ] 4900 5000 5800 6050 6500to upper edge of the insert of 700mm

A

D C

D C

E

F

B

HO series 100 125 160 200 250 315 400

Blow energy [ kJ ] 10 12,5 16 20 25 31,5 40

Max. ram stroke [ mm ] 570 580 640 660 690 700 710Ram depth [ mm ] 420 440 450 500 570 590 590

Min. die height without dovetails [ mm ] 140 150 160 180 180 200 220(upper and lower die)

Frame base width [ mm ] 1700 1740 2290 2290 2550 2800 2800

Overall weight [ t ] 19,5 24 32,5 37,5 51 54 67

Blow frequency [ 1/min ] 110 110 100 95 90 90 90at nominal working capacity

Max. die height without dovetails [ mm ] 280 300 320 360 370 400 430(upper and lower die)

Daylight between guides [ mm ] 440 480 580 580 650 700 700

Frame base depth [ mm ] 1050 1050 1250 1400 1400 1400 1400

Height above floor at a height of floor [ mm ] 3800 3800 4050 4300 4700 4750 4750to upper edge of the insert of 700mmMain motor capacity [ kW ] 30 30 37 45 55 55 2 x 45

Main motor capacity [ kW ] 2 x 55 2 x 75 2 x 90 2 x 90 2 x 132

Page 4: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Pioneering feat

3

Die forging hammer

Technologically and economically,the forging hammer is still thebest forming machine available tothe forging industry. It provides amaximum of forming force coupledwith lowest possible investment oftime, cost and energy.

The forming characteristics of forging hammers are ideal for awide range of commercially available forgings.

Many forgings, especially compli-cated, heavy ones, can only be

produced economically with ahammer.

The use of modern, direct springdamping has eliminated the effectof vibrations generated by thehammer on the surrounding ground.

The sound power level can be considerably reduced by partiallyencapsulating the hammer.

LASCO is the pioneer and inventorof hydraulic power drive systemsfor die forging hammers.

LASCO’s over 60 years of enginee-ring experience and continualdevelopment of hydraulic hammershas maintained its position as aleading international manufacturerof forging machines.

LASCO not only invented the firsthydraulic die forging hammer. Italso delivered the largest and mostof the hydraulically driven hammers in the world.

Page 5: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Hydraulische Pressen in der Massivumformung

4

HO-U/GH

The question as to whether ananvil or counter-blow hammer isthe best machine for a particularapplication is decided by the rangeof parts to be forged and, moreimportantly, by their size.

Up to a working capacity of appro-ximately 200 kJ an anvil hammer

is preferred. To cover this range,LASCO offers the HO-U/HO series.For heavier blanks requiring higherworking capacities, the model GHcounter-blow hammer is preferred.

For almost any older hammer –regardless of manufacture –LASCO offers an energy-saving

method of modernization involvingconversion to the best-suitedhydraulic drive system. Electroniccontrol in combination with ahydraulic ejector in the anvil insertin the lower ram die has madeLASCO die forging hammers suit-able for fully automatic operation.

Versatility

Double-acting hammer

HO-U / HO

Counter-blow hammer

GH

Page 6: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Überzeugend wirtschaftlichProfitability

5

HO

LASCO HO-U 250, 25 kJ blow energy, progammable control.

The freely programmable control ofthe LASCO HO-U hydraulic double-acting hammer provides amultiple of forging solutions and isa further step toward achievinghigher production figures with consistent high quality.

Hydraulic top pressure acceleratesthe ram fastest possible to therequested impact velocity ofapproximately 5 m/s. This meansthat the blow frequency is substantially higher than with agravity drop hammer.

The LASCO HO concept ensures:

high forging accuracy

high blow frequencies

precise energy control

simple, safe operation

suitability for automation

direct spring damping

optimum die life

Page 7: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

LASCO-Konzepte...Progress

6

HO advantages

There are many reasons for choo-sing a LASCO die forging hammer.Here are just a few:

Lower energy costs in compari-son with pneumatic or steamdriven machines coupled withprecise adjustment of workingcapacity and blow frequencyensure maximum efficiency.

Elimination of a compressor orsteam network provides flexibility. The hammer is alwaysready for operation.

Short reversal of stroke andshort contact times considerablyreduce die stress. Optimum dielife is achieved by using controlengineering.

The guiding system maintainsalmost constant clearance inspite of ram’s heat expansion.

Excellent sealing of the pistonrod is achieved with standard -ized seals and one-piece guidebushings.

A fast-acting automatic safetyflap prevents escape of oil.

Varying die heights are enteredby the operator and automaticallycorrected by the control.

The heating system fitted directlyin the oil reservoir ensures thehammer is always ready for use.This is standard on all LASCOdie-forging hammers.

LASCO’s world market experiencein hydraulic power drives was gained from the sale and deliveryof around 1200 successfully ope-rating hydraulically powered ham-mers and hydraulic power driveswith capacities of 6.3 to 400 kJ.This experience forms the basis forthe modern design and construc -tion of these high-performancemachines.

Piston rod

Page 8: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

...im Detail

7

HO design

Insert blockA high-strength, generously sizedinsert block of hardened and tempered steel is keyed into theU-frame.

Solidity

FrameHammers with capacities up to200 kJ are designed with a so- called U-frame. Above this capacity,the counter-blow hammer design ispreferred because of anvil weightand related transport problems.

In the nineteen fifties, LASCO wasone of the first hammer manufac-turers to design and produce theU-frame.

The relatively short ram stroke ofthe double-acting drive enabled

the mass of the LASCO U-frame tobe distributed ideally, ensuringhigh rigidity and solid design. Allcross-sectional variations meet theresults of photo elastic analyses.

The frame is made of alloyed caststeel that has been given a precise, controlled heat treatment.

Frame weight and base area havebeen designed to be mounted onspring damping elements. Frameweight and ram weight are optimally coordinated.

Page 9: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

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HO design

The piston rod is the most stressedcomponent of a die forging hammer. Resulting from scientificinvestigations and evaluation ofpractical experience, both thepiston rod and its anchorage in theram have been constantly opti -mized. The rod is flexible and designed for minimum possiblemass. The selection of a high-grade material that has passedthrough several finishing processesand a demanding surface treatment ensures long life.

Guiding systemThe guide rails of tempered steelare arranged such the influence oftemperature fluctuations betweenram and frame are minimized.

Ram and ram guiding

The solid block ram is made of forged, hardened and temperedsteel. The guidings are X-configu-red and the favorable width toheight ratio of the ram ensuresideal guiding characteristics.Automatic oil pressure lubricationprovides optimal gliding conditionsand minimum wear.

Innovation

Page 10: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

9

LASCO-Konzepte...

Dynamics

HO design

DriveThe encapsulated drive system isinstalled in a cast head adapted tothe demanding working environ-ments in the forge. The head alsoserves as an oil reservoir and ismounted with vibration dampingonto the uprights. The use of a forged control block combiningmost of the important control elements reduces the need forpipework almost completely. Thistype of control system ensureshigh operational reliability andefficiency.

The “heart” of the hydraulic driveconsists of durable axial pistonpumps driven through flexiblecouplings by special three-phasemotors. The hydraulic fluid is constantly purified by monitoredfiltration. Constant, optimal fluidtemperature is guaranteed by automatic temperature control,which, in turn ensures consistentperformance unaffected byambient temperature and operationalconditions and prolonged life ofthe hydraulic fluid. LASCO’shydraulic drives have proved theiroperational reliability over a thousand times. In times of rapidlyrising energy costs, this is onemore reason to choose a LASCOproduct.

Page 11: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

10

HO design

Operator and operational safety aregiven high priority at LASCO. Thisis why LASCO equips its machineswith safety systems that go beyondsafety regulations.

Safety moduleprevents an uncontrolled deliveryof blows. It can also be retrofittedon older LASCO hammers.

Ram safety propcan be swiveled into the workingspace and is electronically controlled.

Piston rod safety coverwith automatic safety flap.

Safety

Page 12: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

11

LASCO-Konzepte...

Performance

GH

LASCO GH 2500, 250 kJ blow energy, weight: approx. 150 000 kg, programmable control.

The experience gained in themanufacture and operation ofhydraulic anvil hammers formedthe basis for development ofhydraulic counter-blow hammers.

With regard to handling, efficiencyand safety, these metal-formingmachines meet the high demandsof the forging industry just as competently as anvil hammers.

The LASCO GH concept ensures:

high forging accuracy

high blow frequencies

suitability for automation

precise energy control

optimum die life

simple, safe operation

direct spring damping

Page 13: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

12

GH design

The rams of the counter-blow hammer have unequal masses. Themass ratio of the upper to thelower ram is 1:4 to 1:5, dependingon size. On smaller counter-blowhammers, the upper ram is guidedinto the lower ram. On larger counter-blow hammers, the lowerram is guided into a solid crossbeam of cast steel that absorbs alllateral forces.

Crossbeam and uprights for thelower ram are connected to eachother with form-fitting joints.Combined spring damping elements may be fitted under thebase.

Innovation

Section through a counter-blow hammer

Page 14: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

13

LASCO-Konzepte...

Safety

GH design

The working principleThe resulting ram impact velocityis around 6 m/s. The ram strokesare constant. Varying die heights,for example after die change, areautomatically compensated.Because of the chosen mass ratio,the lower ram moves at a finalvelocity of only 1.2 to 1.5 m/s.

Similar forging conditions exist asfor anvil hammers. The chances ofthe blank jumping out or shiftingis significantly less than with conventional counter-blow hammerswith rams of similar mass. Theinstallation of ejector systems within the hammer’s working spaceis also facilitated because of theshort stroke of the lower ram and,therefore, also an automation ofthe hammer.

During the reverse stroke, the aircushions located under the lowerram dampen the impact when theram reaches its end position, reducing the forces absorbed bythe foundation and allowing thedissipating energy to be captureddirectly. This is a further advantage in comparison withcounter-blow hammers of conven-tional design.

DriveThe drive system is encapsulatedand installed in block constructionon the head crossbeam. In itsdesign and construction it is, largely, the same as the drive forthe anvil hammer. The lower ramis pressed down against two air cushions into its starting positionby two plungers. The rams are notconnected, neither mechanicallynor with a hydraulic coupling.Their motions are precisely controlled by the hydraulic drivesystem.

FrameThe frame is a multiple elementcast steel and welded construction.It consists of a solid base plate,the uprights and the crosshead.Pneumatic springs for the lowerram drive are installed in the baseplate. The uprights are anchoredcentrally to the base plate, incorporating the guides for thelower ram. The crosshead is fixedon the uprights, carrying the control block for the completehydraulic drive system. In addition, extra guides for theupper ram and the ram-lockingdevice are built into the cross-beam.

Safety systems for the piston rod,ram and ram guidanceThese systems are also largelysimilar to the LASCO HO-U machines.

Page 15: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

14

bility of archiving internal andexternal analogous and binarysignals.

LASCO control concepts aredecentralized on the basis of bussystems. Only hardware of interna-tional industrial standards is selected. This permits customersthe possibility of making adjust-ments and performing maintenancework on their own as well as reprogramming and enhancing at areasonable price. Not least thismeans a high security of invest-ment.

Control

of data can be input simultaneouslyduring operation and the data canbe transferred to the network viainterfaces.

Software modules specific to thecustomer can be linked. Options ofintegrated phone- or internet-aidedonline maintenance systems areoffered.

Efficient interfaces ensure the realtime communication with auto -mation systems and industrialrobots. In principle, a data loggeris integrated and offers the possi-

Enhanced control

Decentralized process controlThe “brain” of every modernmachine tool is its decentralizedprocess control. As LASCO is totally customer focused, all confi-guration and programming is performed in-house.

LASCO’s core competence in soft-ware programming and in thedesign and installation of electronicand electric components allowsthe consideration of all customerrequests that are technically feasible, including the provision ofinterfaces for integration of existing processes and interlinkedoperations.

LASCO process and machine controls offer all the performancecharacteristics of a modern production organization, such as:

centralized, product-related setting and evaluation of allmachine parameters

product data administration,optionally with data base link

operating data registration

product follow-up

integration in MRP

integrated maintenance programme

integrated data logger

The requests of the customer arealso considered, when designingman-to-machine interfaces, as wellas specific screen menus and charts (available in several languages).

The operator is guided by a gra-phic colour display, which is in thesame language as the messagesdisplayed at the terminal. The registration, evaluation and listing

LASCO designes the operator menus and screen forms individually according to the custo-mer’s demand, in this case located in China.

Page 16: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

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LASCO-Konzepte...

Versatility

Options

The variety of forged componentsand materials forces the need forspecial equipment. In order to provide flexible adaptation tovarious forged product ranges,LASCO can offer comprehensiveoptions.

Position and speed measurementWith the help of sensors, the con-troller is able to register the positionof the rams. This allows the energyto be controlled such that therequired thickness of the blank isachieved with highest accuracy. Atthe same time, the energy used foreach blow is measured.

Noise reductionEncapsulation reduces the soundpower level.

Spring damping systemVibrations emitted by the hammercan be absorbed almost completely.Forging hammers have becomeenvironmentally friendly.

Multi-piece frameMulti-piece frames are used for wor-king capacities exceeding 200 kJ. Ifrequired, smaller hammers can alsobe designed with.

Online maintenanceThis system allows access to thecontrol process for service technicians in the LASCO head-quarters. LASCO experts can callup control functions and carry outanalyses, remote diagnosis andonline optimization.

Hydraulic ejectorThese ejectors enable smaller dieangles and closed die forging.

Page 17: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Special, adapted and commerciallyavailable industry robots are usedfor handling. The synchronousmaster-slave operation of tworobots provides a number of benefits: The billet is initially gripped at both ends and then synchronously cycled through theindividual forging operations in the impressions. This allows toforge safely and remove longerblanks in multiple die cavities configured in a row.

Complex requirementsThe forge grippers have to fulfillcomplex requirements:

safe positioning in the impressions

safe absorption of accelerationforces and relief of robot axes

compensation for changes in thelength of the billet

deliberate release when the billet adheres to the upper die

general suitability for thedemanding working environments which exist in the forging industry

ProgrammingThe overall system is programmedvia a special user surface on thecentral process control. The programmer enters the essentialparameters and only a few pointsare taught die installation. Theactual programming of the robot istaken over by the master control.

16

Automation

With the help of modern hydraulics,control and sensing technology,coupled with a whole range ofpatented features, LASCO has drastically enhanced the range ofapplications for die forging hammers. LASCO hydraulic dieforging hammers fulfill all thedemands placed on metal-formingmachines regarding process capa-bility and efficiency. As the firstmanufacturer of machine toolsworldwide, LASCO has realizedfully automation on die forginghammers.

ComponentsA sensor patented by LASCO designed for the demanding envi-ronment which is found in the for-ging industry measures ram positi-on and velocity. The systemdetects, for example, if the die isclosed, whether the part is fullyforged or whether a further blow isrequired. The detected ram speedis compared with the preselectedvalue. This allows compensation tobe made for any external influencesthat may have an effect on thesystem.

The essential key component ofautomatic hammer forging is thepatented forge gripper that holdsthe part accurately in the requiredposition during all operations.

The robot works on the principle ofa human operator: taking up thebillet with the gripper – positioningin the impression – deliberate yielding during the blow (withoutreleasing) – lifting – transferring tothe next impression.

A fully automated die forging hammer fromLASCO with synchronized forging robots.

Robots as operator

Page 18: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

BenefitsThe possibilities for installation ofa forging line are just as diverse asthe parts to be manufactured. Themain advantages of automatichammer forging are:

process stability

exclusion of positioning errors

savings in personnel costs

increase in output

increase quality of the forgedparts

reduction in scrap rate

enhancement of multipleimpression forging

Increase quality and save costs

17

The patented gripper from LASCO is thekey to automation of die forging hammers.

A fully automatic forging line for the manufacture of hand tools.

Longer blanks can be forged in multipleimpressions using LASCO grippers.

Automation

Page 19: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Umfassender ServiceHydraulic drive systems

18

Modernization

All the benefits of the hydraulicdrives from LASCO can be appliedto other types of hammer drives.The HO drive was specially de -signed for the conversion of hammers with short stroke, lightram and limited space in the working space of the hammer.LASCO offers a specially adaptedhydraulic drive for the conversionof long-stroke hammers. This overall concept guarantees highefficiency and accuracy.

Hundreds of completed conversionsand modernizations in the perfor-mance range 6.3 to 125 kJ areevidence of LASCO’s competence.

The conversion of all types of hammers with modern LASCOdrives offers several advantages,including:

energy savings

high blow speed

precise energy control

modern control technology

An old belt lift hammer with 30 kJ of blowenergy converted to hydraulic drive.

A pneumatic double-acting hammer with 40 kJ blow energy, before and after conversion toa LASCO hydraulic drive.

BEFORE

AFTER

Page 20: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

GH series

Technical data

All data are proposals and can be adjusted to customer’s requirements.

A = Max. ram strokeB = Ram depthC = Max. die height without dovetailsD = Min. die height without dovetailsE = Daylight between guidesF = Height above floor

GH series 630 800 1000 1250 1600 2000 2500

Blow energy [ kJ ] 63 80 100 125 160 200 250

Max. stroke of upper ram [ mm ] 430 440 495 500 535 540 550Ram depth [ mm ] 750 900 1000 1100 1200 1250 1400

Min. die height without dovetails [ mm ] 300 320 340 370 400 440 490

Frame base width [ mm ] 2440 2800 3000 3200 3420 3800 4200

Max. stroke of lower ram [ mm ] 100 105 125 125 135 140 145

Max. die height without dovetails [ mm ] 450 500 550 620 700 760 820

Daylight between guides [ mm ] 660 710 770 830 900 970 1040

Frame base depth [ mm ] 1400 1520 1650 1800 1900 2100 2400Overall weight [ t ] 46 57 73 89 112 142 178Height above floor at a height of floor [ mm ] 5100 5700 6000 6200 6400 6900 7500to upper edge of the insert of 700mm

GH series 3200 4000

Blow energy [ kJ ] 320 400

Max. stroke of upper ram [ mm ] 565 575Ram depth [ mm ] 1600 1800

Min. die height without dovetails [ mm ] 570 620

Frame base width [ mm ] 4500 4900

Max. stroke of lower ram [ mm ] 145 150

Max. die height without dovetails [ mm ] 880 960

Daylight between guides [ mm ] 1130 1220

Frame base depth [ mm ] 2600 2900Overall weight [ t ] 240 320Height above floor at a height of floor [ mm ] 7800 8400to upper edge of the insert of 700mm

Schematic of GH hammer.

Main motor capacity [ kW ] 2 x 200 4 x 145

Main motor capacity [ kW ] 2 x 45 2 x 55 2 x 75 2 x 90 2 x 110 2 x 145 2 x 160

Page 21: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine
Page 22: Machines for Die Forging Hammers solid metal · PDF filePioneering feat 3 Die forging hammer Technologically and economically, the forging hammer is still the best forming machine

Oct

ober

2012

www.lasco.com

Headquarters:LASCO Umformtechnik GmbHHahnweg 13996450 COBURGGERMANYPhone +49 9561 642-0Fax +49 9561 642-333E-mail [email protected] www.lasco.com

LASCO FRANCE1, allée des Cèdres78860 SAINT NOM LA BRETÈCHEFRANCEPhone +33 1 3080-0528 Fax +33 1 3080-0584 E-mail [email protected]

LASCO USALASCO Engineering Services L.L.C.615 Harbor AvenueMONROE, MI 48162 USAPhone +1 734 241-0094Fax +1 734 241-1316E-mail [email protected] www.lascoUSA.com

LASCO CHINALASCO (Beijing) Forming Technology Co. Ltd.Huateng Tower, Unit 1706AJia 302, 3rd Area of Jinsong,Chaoyang District100021 BEIJINGP.R. CHINAPhone +86 10 8773 0378Fax +86 10 8773 0379E-mail [email protected]