A Billion Ton Hydraulic Press Forge

Pumps, manifolds and servovalves come together to generate the required flow and pressure control required to operate the world's largest closed-die hydraulic forging press designed by SMS group for aluminum giant Alcoa and used to manufacture supersized titanium and aluminum alloy forgings for both military and civilian aircraft.

A massive press is at the core of a new building housing it and all necessary support equipment for its operation.

Size

The forge press is comprised of an upper and lower platen joined together with four tie rods, as well as buttons placed at two workstations that must be depressed simultaneously in order to activate it. Once all sides of the machine have been cleared of debris, workers can operate it successfully.

Forging presses are powered by pumps that deliver high-pressure hydraulic fluid when required by their operating components, providing power to this massive forging press. At its center lies an immense pump room containing large reservoir tanks holding more than 100,000 gallons.

Weber Metals' state-of-the-art machine is one of only three in the US and will allow them to produce large titanium and aluminum parts with reduced weight, lower draft requirements, and reduced machining steps. They plan on using it to manufacture specialty aircraft and aerospace parts - such as main landing gear beams.

Power

Mechanical forging presses use flywheel energy to power a crankshaft, which in turn drives a pitman arm, which converts rotational mechanical energy into linear movement similar to that seen in an internal-combustion engine piston.

Hydraulic forging presses rely on two primary factors to generate power: pressure and speed. You could apply thousands of tons of force, yet the forging would still cool quicker than it can be produced.

OTTO FUCHS/Weber Metals' $180 million investment in North America's largest forging press will allow it to produce large aluminum and titanium aerospace components for use by commercial and military airframes, landing gears, helicopters, aeroturbines and aeroturbines - not forgetting castings and machined parts used by industry applications - unlike its previous forgeries which only produced castings or machined parts for industrial purposes. Only three hydraulic presses worldwide have ever reached this scale!

Technology

As aluminum, titanium, and other high-strength materials transform aerospace, transportation, and military industries, their forging requires large machines with enormous pressure outputs - known as forges - capable of forging shapes to specification. Such forges create parts that are hard and resistant to failure while meeting demanding standards.

Pumps, manifolds and servovalves combine to ensure this forging giant has the controlled flow and pressure it needs for optimal production. A main ram manifold holds 12 single-delivery PFCS pumps while a 100 mm servovalve controls fast gravity approach mode to lower upper die without applying hydraulic pressure, providing greater speed.

With its deep slide guides, thermal bearing sensors and automatic lubrication systems, this servo forging press is built to withstand constant use over time. Together with regular monitoring cycles and 6-12 month preventative maintenance programs, its life will be extended considerably. When rebuilding time comes around, Alcoa engineers will leverage new technologies which enable this massive press to produce parts never before achievable.

Safety

Any piece of machinery operating with high levels of force requires adequate safety measures for its users, from training sessions and inspecting the machine beforehand, to safeguards to protect those working nearby the machine.

Hydraulic presses are enormous machines with hundreds of components that could fail at any moment and expose workers to the risk of minor to severe injury in their use.

Preventive maintenance can help avoid most problems in machine assembly lines. They must be regularly cleaned, inspected and repaired; hydraulic lubrication systems extend lifespans; failsafe locking mechanisms protect from human error or malfunction; work areas should remain clear of limbs for maximum productivity - these steps may save lives while decreasing risks of catastrophic failure.