"Discussing the Craftsmanship of Forging Machine Components"

Overview of Functional Components in Forging Machinery

In the realm of numerically-controlled machine tools, a distinct category exists that diverges from the traditional functional components found in metal-cutting machines: the components specific to forging machinery. While there is currently no comprehensive classification or definition for these forging machinery parts, their crucial role in enhancing the safety and operational integrity of forging machines is widely acknowledged. The trend towards specialized production of these components, coupled with their promising market potential, has garnered consensus within the industry. This article aims to provide a concise overview of several key functional parts commonly found in forging machinery.

Friction Clutch-Brake Systems

One of the earliest innovations in forging machinery components is the friction clutch-brake system, which has become integral to mechanical presses. This system is essential for the main drive of mechanical presses, as its performance significantly influences the usability, safety, reliability, and overall efficiency of the machine.

Friction clutch-brake systems can be categorized based on their structure and operational characteristics. They are classified into combined and separate types, and further distinguished as either dry or wet friction systems. Additionally, they can be organized by their operating mechanisms, which include pneumatic and hydraulic systems.

The combined friction clutch-brake boasts a compact design, allowing for simultaneous engagement and disengagement. It is commonly installed on both intermediate and crankshafts, finding widespread use in open-type and high-speed presses with capacities ranging from 100 to 1,600 kN. Conversely, the separate friction clutch-brake offers advantages such as reduced rotational inertia and minimized heat generation, thereby extending the lifespan of the friction plates. These are typically utilized in closed presses and larger open presses, although their production is often managed by the original equipment manufacturers due to structural complexities.

Currently, two primary types of friction clutches are produced domestically: the combined pneumatic dry friction clutch and the combined pneumatic wet friction clutch. Both types have reached a level of maturity in the market, providing reliable performance for mass production and supply to mainframe manufacturers.

Optoelectronic Safety Protection Devices

Optoelectronic safety protection devices play a vital role in safeguarding operators working with forging machinery. These devices utilize an infrared light curtain positioned between the operator and the hazardous area of the machine. If an operator inadvertently enters this protected zone, the light curtain is disrupted, prompting the control system to halt the forging process and prevent any potentially dangerous movements.

It is important to note that these devices do not directly protect the operator; rather, they serve as a control mechanism that signals the machine to cease operations before an accident can occur. Therefore, they are more accurately described as optoelectronic safety control devices.

These systems can be categorized into two main types: reflective and radiation safety devices. Reflective devices consist of a controller, a sensor, and a reflector, with the sensor emitting a light curtain that is reflected back to it. Radiation safety devices, on the other hand, involve a controller and two sensors—one for transmitting and the other for receiving the light curtain.

Optoelectronic safety devices can be adapted for various types of forging machinery, including mechanical presses, hydraulic presses, and shears. They can be configured for single-sided or double-sided protection, depending on the machine's operational requirements. The height of the protective light curtain must exceed the maximum stroke of the forging machine's working mechanism to ensure effectiveness. While there are numerous domestic manufacturers of these safety devices, quality can vary significantly, necessitating careful selection by equipment manufacturers to avoid potential safety risks.

Cam Controllers

The cam controller is another critical component within the electrical control systems of mechanical presses. It governs the precise timing and sequence of actions performed by the main and auxiliary mechanisms during the operational cycle of the press. The cam controller operates by distributing the crankshaft's rotational angle, sending signals to the electronic control system that coordinates the actions of various working mechanisms.

In China, many specialized manufacturers produce cam controllers, and the quality of these products is generally consistent, contributing to the reliability of mechanical presses.

Automatic Feeding Devices

Automatic feeding devices are essential for efficiently supplying sheet materials to various types of presses, including open, closed, multi-position, and high-speed presses. These devices typically consist of a material rack, a decoiling leveling mechanism, a pneumatic clamp-type feeding mechanism, and a waste reeling material rack.

The material rack and decoiling mechanism support and level the coiled material, facilitating accurate feeding. The pneumatic clamp-type feeding mechanism utilizes compressed air to control the feeding process, allowing for adjustable stroke lengths to accommodate varying material sizes. Waste material is collected by the reeling mechanism, though it may not be necessary in all applications.

While several manufacturers in China produce automatic feeders, most focus on small to medium-sized open presses. The market for feeders designed for closed presses and transfer presses is likely to see increased specialization in the future.

Stamping Dies

Stamping dies are among the most recognizable functional components in forging machinery, having achieved standardization and professional production early on. These dies are essential for various punching processes—such as blanking, drawing, and cutting—performed by mechanical presses. The die set typically comprises upper and lower formwork, guideposts, and guide sleeves, with many manufacturers producing standard components for medium and smaller specifications.

In China, numerous specialized factories produce stamping die sets, which are increasingly available as standardized components. However, larger die frames are often custom-made and supplied alongside the die by the manufacturer.

Conclusion

In addition to the aforementioned components, other functional parts such as shearing blades, bending molds, and tonnage indicators are integral to the operation of forging machinery. As the industry evolves, the trend towards specialized production of these components is expected to grow, moving away from the traditional model of in-house manufacturing by main engine plants. This shift will allow for enhanced quality and innovation in the production of forging machinery components, ultimately benefiting the industry as a whole.