What Valve For Hydraulic Forging Press?

Forging is a method of plastic deformation using mechanical or hydraulic force. Mechanical forge presses use a flywheel to store energy before driving a ram connected to a crank mechanism.

ME hydraulic presses offer you a cost-efficient solution to hot forging gate valves without defects, cutting production costs and material waste in half. A suitable-sized and configured control valve is therefore of critical importance for production costs to remain reasonable and material waste at an absolute minimum.

Double Stage Pump

Metal forging is an invaluable manufacturing technique when the advantages of casting cannot be ignored, yet micro-cracking in finished product remains an unavoidable risk. To reduce such a threat and ensure smooth operations of forging press, its hydraulic system, including both its pump and hydraulic accumulator group must be well maintained.

Over many years of service, the hydraulic system of a forging press had begun to show signs of wear. This caused significant downtime, pressure loss in the system, erratic operation, inconsistent ram performance, poor quality products and overall poor quality finished goods. To address these conditions, Consolidated Industries in Cheshire CT decided to replace their old pumps with new double stage pumps equipped with hydraulic accumulators groups.

An advanced hydraulic power system allows the forging cylinder to be pre-set to its desired operating force with simple keypad entry on a new drive controller and digital or analog signals from an existing press control. This smart system replaces complex traditional valve controls with simplified operation and significantly enhanced performance not possible from traditional systems.

Smart hydraulic power systems reduce complexity in control systems while simultaneously cutting energy consumption by only turning on motor/pump sets for those few seconds of each cycle when flow is needed, significantly decreasing wear on pumps and motors while simultaneously cutting maintenance costs and saving money through wasted production, labor costs, spares replacement inventory management or inventory inventory reduction.

This 240 Volt Single Phase unit is ideal for home or garage use and comes complete with everything needed to get started. Crafted by professional quality machinery that's meant to outshine performance and last, this machine will bring decades of service before any needed maintenance can even arise.

High Flow Low Pressure

Hydraulic forging presses are highly versatile machines capable of performing numerous tasks such as hot and cold forging, stamping, cold extrusion, straightening, bending, flanging, sheet drawing, powder metallurgy and pressing. Utilizing liquid as its working medium, they can process materials such as metal, plastic, rubber and wood as well as many others that come to them through aerospace, nuclear power or petrochemical industries.

To maximize the performance of a hydraulic forging press, it is critical to understand its hydraulic system. A typical hydraulic press comprises three primary components: hydraulic cylinder, oil tank and control valve. Pascal's law uses energy created in the form of force from Pascal's law to drive hydraulic cylinders while an oil tank stores fluid while control valve regulates how it flows outward. Finally, pressure gauges provide readings of pressure in real time.

Traditional hydraulic forging presses used circuit hardware to manage flow and pressure. Unfortunately, this caused hydraulic fluid to fluctuate during forging cycles, leading to different pumps working at various speeds and leading to sudden spikes in hydraulic piping pressure during loading/unloading cycles resulting in unpredictable ram movement and poor quality forgings; additionally, extended contact time with dies decreased useful life and raised costs significantly.

To address these problems, the company retrofitted its press with an intelligent digital hydraulic drive-system. This intelligent digital hydraulic system monitors, analyzes, and controls system readings thousands of times every second; enabling greater accuracy and consistency of forging process as well as less scrap and rework.

The Metal Forge Complete Hydraulic Press Hardware Kit can be purchased in either single-phase 240V or three-phase single phase form, featuring a 3.7Kw motor & hi-lo pump capable of producing 26 tonnes of force with just single phase voltage; perfect for garage or workshop installations! Complete instructions are also included with this product to get you going quickly.

By-Pass Valve

Hydraulic forging presses are metalworking machines that use high pressure fluid to generate force for plastic deformation of workpieces, producing up to 75,000 tons of force and applying it through a ram attached to either a crank mechanism or large piston that drives it. A bypass valve helps protect main valve by limiting opening resistance while simultaneously protecting it from sudden surges of high pressure from upstream.

A bypass valve is placed into the hydraulic circuit downstream of a control valve and its opening torque can be adjusted to meet process needs. It can be operated manually or automatically via sensor/pressure switch; its closure pressure can also be predetermined or stop hydraulic system operation altogether. Furthermore, this valve features both seat/body seals as well as two-level soft seal pistons to ensure tight sealing pressure with minimal wear and tear.

Block and bypass valves are an efficient way of avoiding shutdown of an entire process unit when repairing control valves, particularly where significant economic loss could be avoided or where operations cannot feasibly operate through bypass. Block valves tend to be one size larger than their respective control valves with lower CV values while their bypass line and valve should have capacity at least equaling or exceeding this calculated or required value, but not exceeding twice it.

A bypass valve can be combined with a back pressure regulator (BPR). A BPR works to regulate fluid pressure at its own inlet by opening and closing to release excess pressure or restrict flow, respectively. A control valve opens just enough for optimal process pressure levels; once these exceed desired limits, however, its inlet valve opens further so as to release any additional tension.

Pressure Gauge

Pressure gauges are essential components of any hydraulic system, serving to monitor operating conditions of presses to ensure they remain safe for operation. There are various considerations when choosing a pressure gauge for your press, including its type, process pressure level, connection size/material choice and leak integrity requirements.

Dependent upon your process, mounting a pressure gauge can vary widely. Some types are threaded while others feature male/female sockets to connect hoses; depending on how large or small your process equipment connections are and whether or not a reducer needs to be added between your pressure gauge and its connections, different connections could be suitable.

Pressure gauges come in a range of materials, from brass to stainless steel. Selecting one depends on your budget, space availability and compatibility with process fluid. Furthermore, consider how well they handle vibrations, pulsations and sudden pressure spikes within your system.

Bourdon tube, capsule and diaphragm pressure gauges come in three basic varieties. Bourdon tubes feature a small curved tube inside that when pressurized straightens out like a balloon. When pressurized again, this causes its diameter to change which interacts with gears to move an external pointer allowing users to read pressure readings easily - they may even be preset at one pressure range or another.

Pressure gauges feature clear windows for easy reading of readings. The window material may include glass, tempered glass or soft plastic; soft plastic allows thermal compensation while also helping prevent glycerin or silicone leakage into the window. In addition, each gauge comes equipped with a pointer that indicates its readings on a scale.

A pressure gauge can help keep an eye on the pressure levels in your forging press, helping ensure it operates as intended. Too much or too little pressure could damage the machine; while too low a level could result in slow up-down speeds. A pressure gauge can help ensure this doesn't occur by monitoring how it functions.