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What is Forging? 

Forging is the process of shaping metal into its finished shape by pressing or hitting it against an anvil or die

Why Use Hilma Quick Die Change Systems?

Hilma has the experience and can take the heat. We have the solutions for handling high temperatures with the correct products and systems suited to the needs of the forging process. By incorporating a Quick Die Change System into your facility you can cut the time of your changeover by half, sometimes more. Die changing is easier for the operator, and may not require a highly skilled die setter. The die change time may also be shortened by preheating the tool outside of the press. In addition you can expect:

  • More parts from one die, reducing die changes
  • Run in periods can be reduced or eliminated since the die is securely clamped, centered and located
  • Longer tool life, due to less wear and tear
  • Finished forging products have a constant high quality level, even after the production of many pieces and frequent die changes.
  • Run-in periods are no longer necessary or can be considerably reduced, since the die is properly centered and located, additional alignment is not needed. 
  • Highly repeatable clamping forces.
  • Reduce setup times
  • Reduce the risk of accidents with a safe die
    change
  • Easy handling of heavy dies/tool

 

Forging Trim Presses

After the part has been forged, trim presses are typically used next in the process. Trim presses do not see the severe environment and tremendous forces seen in the forge press. Because of this, there are more choices when it comes to clamp types such as hollow piston, sliding, fixed mounted clamping bar and others. When the trim press is configured with hydraulic clamps and die lifters to provide a quick die change, there are many advantages including elimination of manual clamping on hot dies, single minute change of dies; which means more press up time, and die lifters and die supports to provide a rolling surface for ergonomic die exchange.

 

Mechanical vs. Hydraulic Methods 

Mechanical clamping method
The clamping force on the forging die is often created by mechanical components such as t-bolts, strap clamps and tapered wedges. The parts are installed and torqued down manually, so the clamping force is dependent on the skill of the die setter and the torque applied to the fasteners. As the size of the fasteners increase so does the required torque for safe clamp forces. After a brief operation of the press, the bolts may need to be retorqued. With these variables in mind, repeatability of the clamp force may vary with the skill and physical abilities of the operator.                      

Advantages:

  • Clamp components are relatively  low cost  
  • Easy Handling
  • Low maintenance cost

Disadvantages:

  • Clamping and unclamping is all manual  
  • High torque and manual effort required
  • Not ergonomic, prone to injury  
  • Time-consuming alignment and adjustment
  • Loose clamp components during change
  • Automation is not possible

 

Hydraulic Die Clamping System Method 
In today’s age of short runs and just in time deliveries, a hydraulic quick die change system for forging applications offers many advantages. The forging dies are locked in place with constant hydraulic pressure. The forces are commonly transmitted with clamps having tapered wedges mating with similar tapers on the die. Wedge clamps provide the advantage of repeatable hydraulic forces with the security of a locking mechanical wedge. Forging dies are quickly clamped and unclamped, thus saving time, which is important when the tools are changed frequently. Special materials and sealing technologies allow for the intense heat and conditions seen in the
forging.

Advantages:

  • Ergonomic
  • Short die changes times
  • Little or no parts handling
  • Less die movement = longer die life
  • Compact  clamp designs
  • Large range of clamp sizes  
  • High, repeatable and adjustable clamping forces
  • Suitable for dual pressure clamp sequence  
  • Repeatable clamp forces
  • Automation  of the process is possible

Disadvantages:

  • Higher investment cost
  • Die modifications may be required
  • Safety and monitoring system required.
  • Hydraulic hose and tubing added  to the upper and lower die clamps
  • Central hydraulic power unit and control package

 

Series Data sheet Technical data

Wedge Clamp 

Data Page 2.2400

clamp your die with a push of
a button.

Wedge Clamps for Forging are designed to suit the adverse conditions of forging, while minimizing press down time. The retracting clamping bolt and its rugged housing help to isolate forging heat and shock loads from the hydraulic circuit. The wedge clamp’s self-locking tapered bolt clamps on a mating 20° beveled surface on the die. An optional series valve integrated into the clamp monitors the position of each cylinder and provides a high level of safety.

Wedge clamps with a vertical clamping bar can be integrated into the lower master die set. The bar further isolates the hydraulics from the heat of the process and can be removed during the tool change. Clamping forces for these wedge clamps range from 22,000 to 143,000 lbs.

Advantages:

  • Self-locking clamp bolt isolates heat and shock.
  • In-die mounting and optional series valve increase safety.
  • High clamping forces range to 143,000 lbs.

 

Learn More 

 

 

Roller and Ball Lifters 

 

 

Data Page – 8.1834A

roll your dies easily into
place

 

Roller and ball lifters make die changes fast and efficient. For heavy loads, for linear movement of dies: On the underside of the roller bar lifting pistons are provided. Pressure is applied to these pistons using hydraulic pressure generators, which lift then the complete roller bar. The die positioned on the roller bars, is not in contact with the table top and can be easily moved.

 

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Die Cart 

 

 

Data Page – 8.89000

Transport dies easily without waiting for

the forklift.

Powered or manual carts that transport dies up to 3600 lbs., and helps the dies to be safely transported in an efficient way.

  • Time-saving die change
  • Safe material transport
  • Exact positioning
  • Safe and easy die transport
  • Improved ergonomics for the user
  • Highest safety by automatic docking station

 

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Carrying Consoles

 

 

Data Page 8.18350

for easy and efficient die
change at the press.

The carrying consoles are hung in the hooks on the die changing side of the press. The hooks are supplied with the consoles. The consoles are used as a pair. Their size must be selected to suit the highest die weight.

 

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Clamping Nut

 

Data Page – 6.2273

manually placed on the clamping
edge of the die.

Following manual positioning of the clamping nut against the clamping edge, the integral gear and the Belleville springs will be preloaded by turning the hexagon nut. As a result, a high clamping force is generated with a small torque.  The required clamping force is reliably displayed by clamping force display and the integrated Belleville spring assembly ensures reclamping of the clamping nut in the case of clamping edge changes.

 

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Power Unit 

 

 

Data Page – 7.1800

control all the clamps and lifters in the

die change system.

For the operation of hydraulic clamping fixtures and other handling and clamping systems on machine tools.

 

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Block Cylinder

 

Data Sheet – B1.5091

Use block cylinders with position monitoring to move dies during production.

 

Block cylinders, single or double acting, are made of high alloy steel, bronze alloy and special aluminium alloys. They can be installed in any position and have a max stroke speed of 0.25 m/s. ROEMHELD block cylinders do not leak oil when static. Stroke leakage is at a minimum due to the double piston sealing.

 

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