Hydraulic powder presses. Cost-effective and flexible

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Joanna Riley
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1 Hydraulic powder presses Cost-effective and flexible

Hydraulic powder presses Forming the future The production of complex sintered compacts of consistently high quality and on economic terms are the demands facing the operators of powder presses.

The industry finally recognised the benefits of powder metallurgy in the 1950s, and since then the technology has enjoyed rapid growth.

2 Hydraulic powder presses Forming the future The production of complex sintered compacts of consistently high quality and on economic terms are the demands facing the operators of powder presses. The parts produced are used predominantly in the automotive industry, but also in the electrical appliances industry and in general machine engineering. The industry finally recognised the benefits of powder metallurgy in the 1950s, and since then the technology has enjoyed rapid growth. The development of new materials and growing demands for near-netshape are now presenting new challenges, but at the same time opening up new and trendsetting opportunities for the powder press technology. Leading in press technology SMS group has played a leading role in the further development of the press technology in powder metallurgy with its innumerable innovations from the very beginning. The company has more than 60 years experience in powder press technology. On the basis of this experience, standards were set in the machine engineering of the powder presses through continuous research and development. For example, presses with PLC and CNC systems were produced as early as 1985, followed in 1990 by a fundamental optimisation of the valve, path and pressure measuring technology allowing presses with press forces from 600 kn to 16,000 kn to be produced. A further trendsetter was then the controlled punch adapter (CPA) technology patented by SMS group. In addition, the press concepts were expanded up to 25,000 kn and the complete part handling technology was integrated into the press. The experts from SMS group use all their experience and knowledge to build new plants and modernize older designs so that even decades later plant operators can still produce in line with market requirements. left: hydraulic powder press with first CNC right: hydraulic powder press, old design 2

High dimensional stability Uniform density No cracking of the compacts

3 SMS group is still today the market and technology leader, providing fl exible and future-proof solutions with continuously optimized processes. High dimensional stability Uniform density No cracking of the compacts Near-net-shape forming Large number of punch levels for complex geometries Minimization of mechanical fi nishing 3

CNC press technology Tailor-made presses, flexible applications With the hydraulic CNC powder press and controlled hybrid press (CHP)

The customer can choose from two press ranges, each with different types and press forces, allowing individual configuration to meet the

While hydraulic presses are based completely on a hydraulic system, the hybrid press series employs a mechanical/hydraulic drive system for

a hydraulic system. Furthermore, the SMS group presses are characterized by a compact form as a four-column press with a low overall height.

implementation of the hydraulic-mechanical drive were commended with the EPMA Award.

4 CNC press technology Tailor-made presses, flexible applications With the hydraulic CNC powder press and controlled hybrid press (CHP) product range, SMS group is able to offer the right solution for practically all applications. The customer can choose from two press ranges, each with different types and press forces, allowing individual configuration to meet the specific requirements. While hydraulic presses are based completely on a hydraulic system, the hybrid press series employs a mechanical/hydraulic drive system for the upper ram enabling the advantages of a highspeed mechanical system to be employed extremely effi ciently together with the precision of a hydraulic system. Furthermore, the SMS group presses are characterized by a compact form as a four-column press with a low overall height. Outstanding technology, intelligent overall concept The CPA process technology developed and patented by SMS group and the excellent implementation of the hydraulic-mechanical drive were commended with the EPMA Award. Compared with other systems, the hydraulic CNC positioning during the whole press cycle and in particular in compacting position impresses with its high precision, product quality, reliability and gentle operation. Coordinated operating heights and arrangement of powder fi lling, adapter changing systems and part handling equipment round out the overall SMS group concept. 4

25,000 kn Repetition accuracy of ± 0,01 mm Product changing in less than 20 minutes

5 1 2 3 Die-set change system for hydraulic CNC powder press 1 Die-set trolley 2 Headplate turning device 3 Tool change station Benefits at a glance Press forces from 600 kn to 25,000 kn Repetition accuracy of ± 0,01 mm Product changing in less than 20 minutes (thanks to short tool and adapter changing times) Energy saving thanks to new hydraulic concepts 5

6 CPA Controlled punch adapter Unique powder press process, universal possibilities The heart of the hydraulic CNC powder presses and the hybrid presses is the controlled punch adapter patented by SMS group. Equipped with up to 12 axes, it permits extremely flexible operation for the production of highly complex sintered parts. With the CPA technology, several punch levels interact, controlled fully automatically and precisely by the CNC system. SMS group offers a broad range of adapter changing systems from simple to fully automated. Furthermore, the controlled punch adapter has a well planned and easily accessible design for simple tool changing. Process engineering of the highest standard The powder is brought into the desired geometry by controlled movement of the punches and allowing for their interaction initially without applying the compacting force. This creates a basic precondition for the later uniform density of the compact. This is followed by the coordinated press compacting process. With the telescopic arrangement of the cylinders, each CPA axis is guided extremely precisely and can transmit high compacting forces. Thanks to the hydraulic CNC axes, the force of all the punches is applied uniformly and the punch expansion is compensated, particularly during the relief phase. The result: Compacts without micro-cracks. Furthermore, the compacting process is made far more precise and controlled for a lasting high productivity and product quality. Press and CPA with 12 CNC axes 6

transfer thanks to uniform punch speeds Hydraulic pressure relief of the punches on both

7 CPA 1200 CPA 350 Benefits at a glance Up to 12 axes (optionally even more) Forces in the axes from 600 to 10,000 kn No risk of cracking in the compacts Optimum flowing powder transfer thanks to uniform punch speeds Hydraulic pressure relief of the punches on both sides after reaching the compacting position Compensation of the elastic punch deflection 7

8 Compacting process 1. Filling 2. Underfill 3.1 Start powder transfer 3.2 Powder transfer 3.3 Transfer position The compacting operation using the CPA method by SMS group is particularly effi cient. It comprises seven fi nely coordinated steps to guarantee optimum product quality. 1. Filling For powder fi lling, the lower punches are already pre-positioned in relation to each other. 2. Underfill To prevent powder losses when the upper punches contact the powder, the die form is lifted. 3. Powder transfer The powder is displaced by individual punch movements without pre-compaction. The powder transfer position is reached when the powder displays the uncompacted partial contour. 4. Compaction The powder is now compacted in a controlled manner taking precise account of the parameters stroke, time and pressure. In the process it is crucial that all press punches reach the compacting point simultaneously. 8

9 4. Compaction 5. Force reduction 6. Withdrawal 7. Release 5. Force reduction To compensate punch spring-back and rob the pressed part of its rebound forces, the upper and lower punches move up and down individually and concerted. 7. Release Finally, the punches are moved back into their initial position. The fi nish compacted part is released and can be removed. 6. Withdrawal The compacted part is carefully exposed and at the same time held by the punches thus preventing cracks in the part. 9

10 Savings in cost and time Complex parts in near-net-shape quality The more precise the forming contour of metal powder parts, the less further machining is necessary. The resulting savings potentials in time and costs are enormous. The CPA compacting method from SMS group is far superior to conventional compacting methods as far as near-net-shape parts are concerned. Comparison of the compacting methos The diagram shows the difference between the CPA compacting method and conventional compacting. At the start of the controlled compacting movement, the two methods are identical with respect to proportional speed of the lower punches to the upper ram speed (points 1+2 in the diagram). With the conventional compacting method with fixed stop, a deflection point is reached with the upper ram speed being followed due to the insufficient counter-force (point 3). The compacting position is then reached prematurely on the mechanical fixed stop with final compaction being effected only by the upper punches (point 4). With the CPA compacting method, on the other hand, the process is linear and uniform with all the controlled press punches reaching the compacting positions simultaneously with high counter-forces (point 5). Compacting point Force curve with linear compacting speeds The diagram shows the compacting speed (depending on compacting stroke) up to the compacting position of the upper and lower ram systems. All the press axes have then own compacting speed adapted to the stroke in order to finally reach their compacting positions simultaneously with high counter-force. Exponentially increasing forces of the press axes up to compacting position with constant compacting speeds. Stroke [mm] Transfer position HK4 HK5 HK6 Compacting position Time [sec] Stroke (mm) Force [kn] HK5 HK6 HK4 Time (sec) Upper ram curve Die curve Lower punch curve Lower punch curve (conventionel) Stroke [mm] 10

New approach for future technology Powder presses produce predominantly components for the

based company SMS group adapted its press technology to a completely new application in a very

SMS group supports us in developing a new market in the area of Green Technology.

with SMS group, says Mike Cuddy, Procurement Manager, GTP.

11 New approach for future technology Powder presses produce predominantly components for the automotive industry. Not so at Gobal Tungsten & Powders (GTP). For this U.S. based company SMS group adapted its press technology to a completely new application in a very short time period. With its HPM 1600E5i GTP manufactures components for fuel cells. SMS group supports us in developing a new market in the area of Green Technology. Success in this process requires a combination of technology and effi ciency which we have found with SMS group, says Mike Cuddy, Procurement Manager, GTP. The HPM 1600E5i impresses with its precision, speed and high process reliability. The optimized hydraulics warrant minimum energy requirements. This is how SMS group understands customer focus. 11

Process and quality control The intelligence of the presses The CNC system of the powder presses has a clearly structured and easy-to-use operator interface.

12 Process and quality control The intelligence of the presses The CNC system of the powder presses has a clearly structured and easy-to-use operator interface. Machine operators are therefore familiar with the machine and its functions within a minimum of time. Easily comprehensible programming applications, actual value/nominal value real-time analyses, fault displays and diagnostic functions are available. The process data for repeat parts can naturally be saved in a database, thus shortening the set-up time in the future. Benefits at a glance Easily comprehensible visualization Fully automated process control Fully automated quality control Statistical evaluation for process or production optimization 12

Oscilloscope diagram for all functions Automated quality functions When data are entered, the CNC system performs a plausibility check, thus

It provides all the operating data for the compacting process, monitors the sensors, compares actual and nominal values and records all the

With the continuous quality documentation, plant operators can meet the demands of the relevant standards or the customer s specifications

Operation flow The compacting force curves of all the press axes involved in the process are also monitored and recorded in relation to their

13 Oscilloscope diagram for all functions Automated quality functions When data are entered, the CNC system performs a plausibility check, thus helping to avoid operator errors. It provides all the operating data for the compacting process, monitors the sensors, compares actual and nominal values and records all the vital process data for quality assurance as part of the statistical process control (SPC). With the continuous quality documentation, plant operators can meet the demands of the relevant standards or the customer s specifications without additional work. Parameters monitored are i.a. the position and force of the top and bottom punches and the part weight. Operation flow The compacting force curves of all the press axes involved in the process are also monitored and recorded in relation to their preset tolerances. The statistical evaluations serve for both process and production optimization on the machine and for quality documentation. The CNC system can be integrated into a network so that the recorded SPC process data can be forward directly to the responsible employee. Actual machine values Production values 13

System solutions Modular components, harmonized interfaces SMS group offers complete system solutions for a press centre from a single source.

14 System solutions Modular components, harmonized interfaces SMS group offers complete system solutions for a press centre from a single source. The advantages: The modular components in the mechanical equipment and software allow gradual expansion and individual adaptation. The interfaces in the electrical and automation system and in the mechanical equipment are harmonized so that smooth and productive operation is immediately assured. After evaluation in advance, SMS group can also integrate existing equipment into an overall concept. Hydraulic powder press line HPM 1000 E5 Peripherals Controlled punch adapter (CPA) with or withoutpunch prelift and conventional multi-platen adapter Adapter transport equipment with integral clamping and positioning device Press tools of tool steel and carbide metal (die, punches, mandrels) Handling equipment such as small manipulators, pneumatic or hydraulic pick-and-place units, conveyor belts and deposit systems Measuring and testing equipment for checking the tolerances of the compacts Magazining devices such as turntables, pallets, indexed feed and removal systems and further logistics components 14

Hydraulic powder press line CHP 160 Compaction force Line of types Hydraulic CNC presses 600 2,000 kn HPM 60 E5 HPM 150 E5 HPM 200 E5 2,500 3,500 kn HPM 250 E5 HPM 350 E5 5,000 8,000 kn

15 Hydraulic powder press line CHP 160 Compaction force Line of types Hydraulic CNC presses 600 2,000 kn HPM 60 E5 HPM 150 E5 HPM 200 E5 2,500 3,500 kn HPM 250 E5 HPM 350 E5 5,000 8,000 kn HPM 500 E5 HPM 650 E5 HPM 800 E5 10,000 17,000 kn HPM 1000 E5 HPM 1500 E5 HPM 1700 E5 20,000 25,000 kn HPM 2000 E5 HPM 2500 E5 Hybrid CNC presses 1,600 3,200 kn CHP 160 CHP 250 CHP

Fields of application and references Unlimited possiblities Powder presses from SMS group permit a broad product spectrum to meet present-day and future demands.

These include, for example, surface-contoured interconnector plates, the key components in high-temperature fuel cells.

That is why leading compact manufacturers rely on SMS group as partners.

16 Fields of application and references Unlimited possiblities Powder presses from SMS group permit a broad product spectrum to meet present-day and future demands. High-strength materials and even green products are increasingly being produced on the machines. These include, for example, surface-contoured interconnector plates, the key components in high-temperature fuel cells. Thanks to the flexible modification and cost-effective expansion possibilities of the presses, plants operators can be sure of investing in a future-proof technology. That is why leading compact manufacturers rely on SMS group as partners. Examples of potential applications Compacting of complex metal powder parts Production of compacts from powder materials such as iron alloys, ceramics, metal oxides, carbide metal, ferritic and graphite powders Sinter forging Composite compacting Sizing Excerpt from the reference list Ames Group, Spain Chepetsky, Russia DAAZ, Russia Federal Mogul, England, France and India Forschungszentrum Jülich, Germany GAZ, Russia GKN Sinter Metals, USA, Canada and Germany GTP, USA Han Dok, Korea Miba, Austria Netshape Technologies, USA Ningbo Tongmu, China PMG Füssen, Germany Plansee SE, Austria Schunk Group, Germany Stackpole Canada Inc., Canada Toyota Motors, Japan University Hanover IFUM, Germany University Kassel, Germany 16

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20 SMS group GmbH Business Unit Forging Plants Closed-Die-Forging Ohlerkirchweg Mönchengladbach Germany Phone: Fax: P-313E Published on Circulation 500 Printed in Germany KD The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.

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