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Solid Forming Machines Cross-Wedge and Forging Rolls
Near-net-shape Solid Forming
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What we offer
Over 300 LASCO experts are united by one goal- to build the best machines for the success for their users.
A LASCO RCW 900 forging roll integrated in a production line for crankshafts at a Germanautomotive supplier.
As a machine tool manufacturer,LASCO has concentrated since itsbeginnings on making available tousers in industry and its relatedtrades machines and equipmentthat provide solutions for metal-forming tasks. Our over 140 yearsof experience gained has given usthe capability to offer productiontechnology that is speciallyadapted to the rugged workingenvironments of the metal-formingindustry. Meanwhile, we can countover 1000 companies in our list ofcustomers in 53 countries aroundthe globe working in fields of allkinds.
Mainly automated manufacturingcells can meet the growingdemands for solid forming offorged parts with reproduciblequality and the most effective useof materials. Closeness to finalcontours (near-net-shape) andefficient pre-forming of materialare becoming increasinglyimportant in these manufacturingcells. LASCO is meeting thesemarket demands with its ownproduct range, which includeshydraulic presses, drop-forginghammers, screw presses andautomation technology, all coupledwith its own machine concept forsolid metal pre-forming usingcross-wedge and forging rolls.
Hydraulische Pressen in der Massivumformung
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Basics
The various markets arecontinuously demanding ever-higher quality of forged parts forfalling prices. One possiblesolution allowing suppliers toadapt to this trend is theautomation of complete forgingcells. LASCO has been supplyingforging machines to its customersthat offer the possibility ofautomation for many years now.
To be able to achieve the samedegree of automation in materialpre-forming using rollingmachines, a new concept has beendeveloped for pre-formed andfinished part production.
Pre-forming lowers costsThe material cost element of unitcosts for die forgings is 30 – 50percent. For this reason alone,optimal pre-forming is essential toreduce these unit costs. The goal,therefore, is to achieve maximumcloseness to the final form withthe help of material distribution atan early stage of production. Goodinitial distribution of materialreduces material flow later in the
forging die, increasing the die’sworking life.
Two rolling processes1. The cross-wedge roll is designedfor the pre-forming and net-shapeforming of symmetrically rotatingsteel and aluminium forgings. Hot,round rods are fed to the cross-wedge rolls and rolled between twosynchronized rollers fitted withtools and preformed such that aworkpiece is created having thedesired shape.
Two guide rails are used to supportthe rods during the pre-formingprocess. The stationary workpiecerotates between the rollers and ispositioned exactly in the geometriccentre of the rollers. Oncompletion of one roller rotation,the workpiece is ejected throughan aperture in the rotating roll tooland transported away for furtherprocessing.
2. The forging roll is designed forthe pre-forming of round andsquare material. In contrast tocross-wedge rolling, the blank is
fed radially into the rollers by amanipulator and pre-formed inindividual sectors (passes). Thecompleted blank is then laid on aconveyor and fed to the mainforming machine.
Both rolling processes offer aseries of advantages:
Considerable material savings.
Improved workpiece surfacebecause of descaling.
Improved die life in subsequentforging because of descalingand reduction of material flowin the die.
Cross-wedge rolls – synchronous rotation. Axial workpiece feed. Forging rolls – counter-rotation. Radial workpiece feed.
Market Demands
Überzeugend wirtschaftlichEfficient Material Distribution with Rolling Machines
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Basics
The difference in material consumption becomes obvious in a comparison of the stages of a forming process with and without pre-forming with rolls.
Pre-Forming on Cross-Wedge and Forging Rolls
Lever
Without pre-forming machineMaterial consumption: 100%
With upstream cross-wedge rollMaterial consumption: 66%
With upstream forging rollMaterial consumption: 67%
Connecting rod for trucks
Without pre-forming machineMaterial consumption: 100%
LASCO-Konzepte...Fundamental Quality Features
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LASCO Concepts...
LASCO cross-wedge and forgingrolls offer an abundance ofinnovative details that predestinethese pre-forming machines foruse in highly automated seriesprocesses and flexible production:
Low maintenance requirementbecause of the omission of fixedtransmission couplings and thecoupling/brake combination.Programmable speed profilesallow adaptation to the formingtask.Direct drive from a torque motorto each roller.
Reliable absorption of formingforces and the thermalexpansion induced by theprocess. Maintenance of narrowtolerances in the roller gap, thusincreasing workpiece precision.High roll frame stiffness.
No roller tension, short rollerchange times.Hydraulic clamping of the rollerbody.
Roller change within 5 to 10minutes depending on roller size.Roller change manipulator.
High parallelism and precisionof the roller gap maintains tighttolerances on the workpiece.Multiple tool resetting ispossible.Measurement and automaticcorrection of the roller gapunder operational loadconditions; large setting rangefor the roller gap.
Constant temperature ensuresconstant forming conditions.Optional tempering of rollers.
Reliable repeatability of allengineering parameters.Programming of all product-specific machine parameters.
Base frame and roller arrangementThe roll frame is, depending onsize, either a compound structure,pre-stressed by tie rods or a rigidsingle-piece welded frame. Solidbearing supports with sphericalroller bearings for the rollers areincorporated in the frame. Therollers are synchronously height-adjustable through synchronousadjustment of the lower bearingsupport.
The guides for the bearingsupports are welded into the frameand the guide rails are adjustable.
Direct driveThe main task in the design of thedrives was the elimination of thefixed transmission coupling of theroller drives. The use of twoseparate torque motors eachdriving through compact speedreducers successfully solved thisproblem.
The high dynamics and controlaccuracy of the motors allow theprogramming of speed profiles.
Both rollers are provided withabsolute shaft encoders formeasurement of shaft angle, sothat start and tool changepositions can be automaticallyapproached. The controller canalso make tool angle corrections.
The basic concept with itsseparate roller drives allowschanges in the direction of rotation(synchronous or counter rotation).This makes possible the use ofcross-wedge or forging rolls withpractically the same method ofconstruction. A combination rolldesign using both processes is alsopossible in special cases. Thisprovides the user with substantialadvantages when a change in theproduct range is necessary.
Torque motors drive the rollers individuallythrough compact speed reducers.Synchronization is achieved using a closedloop control system.
The roll frame: composite construction andpre-stressed with tie rods.
circulation or with grease. The oilconducts away the heat that entersthe system via the rollers. Thisstabilizes the temperature in thebearing supports.
RollersThe rollers are fitted with crosskeyways that ensure precise fixingand centralizing in the machine.The torque needed for the formingprocess is applied through stabledrivers on the rollers. The rollersthemselves are made of forged,annealed, tempered steel. Thetools are attached to the rollerperiphery using T-slots.
Hydraulic roller clampingNo auxiliary tools are neededduring automatic roller clamping.The rollers are hydraulicallyclamped and locked, whichensures a high degree of safety. A roller change is completed in avery short time.
Roller change manipulator LASCO rolling machines can beoptionally fitted with a fully or
...im Detail
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...In Detail
The drive unit was simplifiedconsiderably in comparison withconventional drives, a fact thatwas extremely advantageous forthe operation, setup operations(roller changes) and machinemaintenance.
Bearing supportsEach roller is supported at eachside by twin-row spherical rollerbearings designed for extrareliability. The bearings in theright-hand upright can be recessedhydraulically for a roller change sothat the adapters can be freed andthe rollers removed without toolsby an integrated changing device.
During operation, the rollers areclamped hydraulically in the axialplane. This hydraulic cushion alsoserves to compensate for thermalexpansion in the roll frame. Thissuccessfully eliminates axial rollertension.
Bearing cooling and lubricationDepending on size, the bearingsare lubricated either by oil
Pioneering Solutions
Hydraulic roller clamping.Temperature control of the rollers.
semi-automatic roller changemanipulator, which lifts the rollersout of the machine with liftinggear. This device is designed withtwo cable reels that keep therollers positioned centrally.Travelling and lifting gear areprovided with creep and fastspeeds.
The motors are driven by afrequency converter that ensuresthat all movement is soft andharmonious. Using this system inconjunction with hydraulicclamping, a roller can be changedwithin approximately 5 to 10minutes.
Temperature controlThe use of the temperature controloption is recommended forsensitive materials such asaluminium alloys. The rollers areheated to the desired temperatureeither with preheated thermo oilcirculating in a closed circuitsystem or internally by electricheaters.
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QKW Series
The LASCO QKW cross-wedge Rollis designed for fully automaticoperation as a pre-formingmachine in forging line seriesproduction. Basically, however, itcan also be employed as a stand-alone machine. It is especiallysuited to the pre-forming andfinish forming (materialdistribution) of rotation-symmetrical billets of steel andaluminium.
The processRound, heated billets are fed tothe cross-wedge roll and rolledthrough between two synchronizedrollers fitted with tools andformed. On completion, theworkpiece is ejected through anaperture in the rotating lower rollerand transported away for furtherprocessing.
Guide railsDuring forming the workpiecerotates freely – in the oppositedirection to roller rotation.Twoguide rails are used to support theround rods in the correct positionduring the pre-forming process.
The rails are fitted with overloadprotection in the form of reversibleflap devices. Control sensorsdetect any irregular occurrencesduring operation and theworkpiece is ejected before theforming equipment can bedamaged in any way.
Optionally, the rails can be fittedwith hydraulic drives that retractthem just after the start of rolling.
Roller gap adjustmentThe roller gap adjustment is set upby synchronous adjustment of thetwo lower bearing supports usingtwo servo-driven, positionablespindle drives.
The system is provided withmeasuring equipment having high-resolution absolute sensors thatmonitor the position of the rollersduring operation and automaticallycorrect the gap by adjusting thespindle drives, compensating formechanical and thermal changes.
Fully Automated Cross-Wedge Roll...
Automatic workpiece feed.
Guide rails (shown here schematically) keepthe rolled workpiece in its central position.
Parts formed on a cross-wedge roll.
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LASCO-Konzepte...
... with Short Set-up Times
QKW Series
Workpiece feedThe heated blanks are taken up bya chain feed and pushed into thetransverse conveyor. This isprovided with a reject pointcontrolled by sensors that separateblanks with too low a temperature.The transverse conveyor pushesthe blank into a guide system anda servo driven rod pushes theblank axially into the start positionof the forming process.
Roller change manipulator. A roller is changed in less thanfive minutes.
Schematic representation of a LASCOQKW 700 cross-wedge roll with feedguide system.
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RCW Series
LASCO RCW series forging rolls aredesigned such that the stretchingprocess is completed in severalpasses (roller groove). The blankentering from the heating unit isfed sequentially to the individualpasses by a forge-rollingmanipulator. The blank is pre-formed analogous to the contoursof the individual roller grooves.Between the individual passes theforging roll manipulator arbitrarilyrotates the blank by up to 180°around its longitudinal axis.
As the rollers can be removed fromthe forging roll for a tool or groovechange, it is possible to work withcompletely circular, closed rollergrooves and/or with grooves in theform of circular segments.
Special forging roll manipulatorTo be able to take advantage of allthe benefits of the flexible drivesystem, a specially modifiedindustrial robot is used as amanipulator. The LASCO manipu -lator gripper is fitted with acompensating member thatbalances out the changes in blanklength caused by the formingprocess and a further compen sa -ting member that prevents thereactive forces resulting from theforming process affecting the robot.
This allows feed and discharge ofthe blank to be just as flexiblyarranged because the freelyprogrammable forging rollmanipulator is not tied to a fixedsequence of movement.
The manipulator and the rollerswork in a master-slave modeduring the rolling process with theangle of roller rotation acting asthe master signal. This mode ofoperation allows shock-freeworking and ensures almost zerowear compared to mechanical,rigidly coupled drive systems.
Highly dynamic and preciselypositioning servo motors drive theforging roll manipulator. Itsmovements are synchronized withthe servo drives of the rollers sothat the stretched workpiece ismoved according to the prevailingperipheral speed of the rollers.This means that during operationthe speed of workpiece movementis matched to the speed profile.
Forging Roll with Flexible Drive System…
Forging roll manipulator with special grip-per and compensators.
Parts formed on a forging roll.
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LASCO-Konzepte...RCW Series
Schematic representation of a LASCO RCW 900 forging roll with manipulator.
Tried and tested componentsAll the advantages of LASCOcross-wedge rolls such as rollerchange manipulator for fast toolchange and roller temperaturecompensation are available on theLASCO RCW series.
Flexible multi-purpose rollLASCO is the only manufacturerthat has implemented a conceptfor rotational press forming thatallows both forge rolling work andcross-wedge rolling work to becarried out in one machine. Thisunique and outstanding flexibilityhas been made possible using theprinciple of directly driven rollersin synchronous or counter rotation.
...and Specially Adapted Manipulator Robot
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In the example the billet is fedfrom the heating unit to the inputof the cross-wedge roll and then,after the rolling process, laiddirectly on the conveyor feedingthe working area of the hammer.
The precisely positioned workpieceis picked up by the forging robotsand fed to the individualprocesses. The finished part is laidon a swivel arm that positions thepart in front of the trimming press.Two further trimming robots acceptthe part and place it in the punchand /or trimming tool. A bypass isinstalled between the heating unitand the hammer for parts that arenot to be pre-formed.
In Practice
The advantages that can be gainedby integrating LASCO rollingmachines into an automatedprocess chain are shown by apractical example of an automatedhammer forging production lineworking with a cross-wedge roll.
Cross-wedge rolls can beintegrated into automated forginglines to high advantage because oftheir continuous cycle ofoperations.
Cross-wedge pre-forming not onlysaves material but also reducesthe number of operations andhammer blows in the main forgingmachine – in this example a drop-forging hammer – which results ina significant reduction of cycletimes.
Cross-Wedge Rolling in the Automated Hammer Forging Process
Layout of an automated forging cell with integrated cross-wedge roll:1 = Cross-wedge roll2 = Drop forging hammer3 = Punch and trimming press4,5 = Forging robots6 = Feed robot7 = Transfer robot8 = Die maintenance9 = Swivel unit
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LASCO-Konzepte...
Automatic Roller Change
In Practice
Umfassender ServiceLASCO’s Added Value
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Comprehensive Service
Our experienced experts design allthe components of a productionline that have a decisive effect onproduct quality here in-house.Because of the flexibility and fastdecision-making capabilities of amedium-sized company this makesit possible to react comprehensivelyto customer needs and to offer
LASCO’s workforce, working together ininterdisciplinary teams, will find the optimal solution to your forming require-ments.
Experts in sales, design, production, assem-bly and service make it possible for LASCOto react flexibly and comprehensively to theneeds of its customers.
perfectly harmonised solutionsfrom a single source.
Complemented by our personalpresence around the globe, LASCOcan offer its customers servicesthat have set standards in theworld market.
Perfectly harmonized solutions from a single source
Series QKW and RCW
Technical Specifications
QKW series 500 700 1000
Roller diameter [ mm ] 500 700 1.000
Billet diameter max. [ mm ] 50 70 110
Main-drive power per roller [ kW ] 22 55 90
Width including feeding unit approx. [ mm ] 3.000 5.000 6.200
Roller width [ mm ] 500 700 1.000
Billet length max. [ mm ] 300 400 560Adjustment lower roller approx. [ mm ] 40 60 80
Roller tempering optional optional optional
Depth approx. [ mm ] 1.500 2.400 3.600Height approx. [ mm ] 2.000 3.300 4.700
Weight incl. rollers approx. [ kg ] 15.000 25.000 50.000
Schematic diagram of the QKW cross-wedge roll
Further models and sizes available on request
RCW series 460 560 930
Thickness of billet max. square [ mm ] 63 80 125
Weight incl. tool approx. [ kg ] 1.200 2.200 8.000
Main-drive power per roller [ kW ] 125 200 500
Width approx. [ mm ] 3.800 4.800 7.500
Outer diameter of tool [ mm ] 460 560 930Clamping width of tool [ mm ] 560 700 1.120
Length of billet max. [ mm ] 315 400 630
Adjustment of roller [ mm ] 20 25 30
Roller tempering optional optional optional
Depth (without roller changemanipulator) approx. [ mm ] 1.200 1.500 2.400
Height approx. [ mm ] 1.800 2.300 3.500
Weight incl. rollers approx. [ kg ] 15.000 25.000 100.000
Schematic diagram of the RCW forging roll.
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 BRETÈCHEFRANCEMonsieur Thierry LebaillyPhone +33 1 3080-0528 Fax +33 1 3080-0584 E-mail [email protected]
LASCO USALASCO Engineering Services L.L.C.1111 Bellevue AvenueDETROIT, MI 48207 USAPhone +1 313 579 1100Fax +1 313 579 2674E-mail [email protected] www.lascoUSA.com
LASCO CHINABeijing Office5 Xisanhuan Beilu100089 BEIJINGR.P. CHINATelefon +86 10 6873 1775Fax +86 10 6873 1052E-Mail [email protected]
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