A design scheme of forging automation production line for electric screw press

2019-10-17 15:09:18

The electric screw press has the advantages of controllable energy and high forging precision, which is widely used in precision forging of various materials. Based on the analysis of the structure and characteristics of the electric screw press, this article puts forward a scheme of forging automation production line based on electric screw press.

Electric screw press selection of forging automation production line

J58k electric screw press is a new type of general precision forging equipment, which is the upgrading product of friction press. The motor drives the flywheel directly by gear transmission. The main engine has simple structure, short transmission chain and high efficiency. However, the requirements for the drive system are very high, the torque response is fast, the output is stable, and the temperature rise of the motor can not exceed the allowable range.

• The strike energy is accurate and controllable, and precision forging is used.
• It has moderate Strike ability, short touch time and long die life.
• Large effective energy, high working efficiency and energy saving.
• It has simple structure, safe operation, simple operation and easy maintenance.

Main system functions of electric screw press

• Mechanical transmission structure. It adopts gear transmission form, with high transmission efficiency, large effective energy, simple main machine structure and less maintenance. The main parts, such as fuselage, screw and so on, are designed scientifically and reliably by means of finite element analysis.
• Motor drive system. Using the latest AC asynchronous motor drive scheme based on direct torque control technology, the torque response is fast and the output is stable, without impact on the power grid. Using abbacs880 system frequency converter and the special AC asynchronous motor for electric screw press jointly developed by the company, the quality is reliable and the performance is stable.
• Only control system. The special control system with self-developed open architecture has high degree of automation, simple operation and complete functions, which can be easily extended to full-automatic production line.
• Effective energy detection. The test is carried out according to the upsetting method of copper column specified in the national standard. The results show that the effective energy of j58k electric drop line press is over 85%, high efficiency and energy saving.
• Overload safety protection. Combined flywheel is adopted for equipment of 1000 tons and above to ensure safe and healthy use of the equipment.

Auxiliary equipment of electric screw press forging automation line

Die base and die base heating system of electric screw press

The forging temperature range of titanium alloy is very narrow. The temperature and heat preservation of die and die base become the prerequisite for forging forming and quality assurance. The die base and supporting die base automatic heating system must be equipped.

The heating mould base is heated by heating rod, and the mould is heated and insulated by means of heat transfer to achieve the preheating effect on the mould core. This will be conducive to the filling of the blank in the forging process, improve the product quality, and improve the die life.

The heating temperature of the mold base can be set according to the customer's requirements. The heating temperature of the mold base is 200 ℃ ~ 300 ℃, generally around 250 ℃, and the temperature control accuracy is not more than ± 5 ℃; the upper and lower mold bases are respectively displayed and recorded with the heating temperature. Mold base from room temperature to set temperature can be set and modified in a certain range according to the needs of customers.

Automatic forging robot of electric screw press

It's a good welfare for forging industry to replace artificial labor with robots. Forging industry is famous for its hard work. Many young people are unwilling to engage in forging work. Many old hard workers still stick to their jobs, which brings challenges to the stable production of forging factory. Forging is not a repetitive work. It requires skilled forging workers to be fast and precise. Under the background of advocating the new era of industry 4.0, the role of forging robot is gradually highlighted. The main performance of forging robot in the application process is as follows:

• The loading and unloading robot takes out the blank forging and replaces the original production line to fully forging automation production.
• The forging robot takes out the product from the stamping die and puts the product into the die.
• After the manipulator takes out the forging in the cavity, carry out the next step of transmission.
• Automatic feeding system for forming raw materials and waste recycling system.
• Production control system of the whole plant, etc.

Descaling machine for forging automation production line

Because forging is to extrude, press, forge and punch metal materials in the hot state, if forging scale is not removed, it will be pressed into the product to affect the structure, so forging scale treatment machine is very necessary.

• Before preforging, the first layer of scale can be well removed from the billet or raw material after heating. (very thick)
• After pre forging, the forging graphite emulsion left in the preforging die cavity can be well removed.

Anyang electric screw press forging automation production line turnkey project

The whole solution design process of electric screw press forging automation line

• Forging process design. The forging process was designed according to the product characteristics and user requirements, and the feasibility of the forging process was verified by numerical simulation.
• Selection of forging equipment. According to the process plan, select the forging equipment type, tonnage and other parameters needed for each process step, and consider the feasibility of forging automation of the whole line.
• Forging die design and manufacturing. Use CAD \ CAE \ CAM and other processes to complete the design of forging die, die base, etc.
• Auxiliary peripheral system. According to the needs of forging automation process design, design and manufacture the die changing system, spray system, mould loading and unloading system, etc.
• Full forging automation integration. After the manual trial production is smooth, the automatic production of the whole production line is completed, and the on-site personnel are trained in automatic production.

Anyang forging Press has more than 60 years of forging equipment production experience. As a leading enterprise in the domestic forging equipment manufacturing industry, we can provide customers with a full range of forging automation production line turnkey project, from equipment selection, design, manufacturing, to site installation, personnel training, and later equipment maintenance and other after-sales services. So far, Anyang Forging Press has designed and produced many forging automation production lines for customers in Russia, Vietnam, the United States and other countries. Please contact us, Anyang Forging Press will not let you down!

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