10000 Ton Heavy Duty Metal Forging Hydraulic Presses

• Warranty: 12 Months
• Feature: High Efficiency
• Customized: Customized
• Model NO.: ZD
• Condition: New
• After-sales Service: Overseas Services
• Power Source: Hydraulic Pressure
• Advantage: Use Widely
• Forging Forming Method: Free Forging
• Structure: Three Beam Four Columns
• Control: Manual and Linkage
• Hydraulic System: Two Way Cartridge
• Certification: CE
• Type: Hydraulic Machine
• Transport Package: as Required
• Specification: CE
• Origin: China
• HS Code: 8462919000
• Production Capacity: 10 Set Per Year

Product Description

Open die forging press
800t-15000t
Oil hydraulic
Working pressure 25MPa, 31.5MPa, 63MPa, 100MPa
2-column / 4-column
Prestressing frame
Welding beam / casting beam
Moveable working table
Rotary forging table
Rexroth pump
Special designed cartridge valves
Siemens PLC
 1,Main functions and features
1.1 Main functions:
This press is mainly used for traditional open die forging process
(billet cogging,upsetting,stretching,bending,twisting,cutting,offsetting,etc).
1.2 Features:
1.2.1 The control system has two working modes: maunal and linkage.In linkage mode you can fast stretching and fast reaming. The size control precision is: ±2mm. The frequency of high speed forging is more than 60 times/min.
1.2.2 The hydraulic system adopts two-way cartridge valve integrated system, and electrical control system is PLC programmable controller, operation reliability. 
1.2.3 There is positioning mechanism to measure and control the position of the slider and movable working table. 
1.2.4 The hydraulic press linkage with forging manipulator,one driver operate the press & manipulator.
1.2.5 The press has a pressure rating function,save energy,improve efficiency. 
1.2.6 It has reliable measure of fire protection. 
2,Overview of structure
The press is four-column structure,mainly consist of main frame,cylinder,moving working table, hydraulic system, electric control system, lubrication system and other components. Through the pipe and electrical installations combined to form a whole, the main parts of the structure are described as below.
2.1 Main Frame 
Main body is consisting of the upper beam, slider, table, column, lock nut, adjusting nut and so on. Host beam, table with the lock nut tightened force fixed to form a closed frame. The master cylinder, return cylinder are installed onto the up beam horizontal center line, the cylinder piston rod connected with the slider, the driver depend on four columns for the slider up and down direction. The master cylinders are plunger-type structure, center cylinder output force is 18000kN,each of the two side cylinder output force is 6000kN.
2.1.1 Upper Beam
Upper Beam is cast steel ZG270-500,annealing treatment after casting,stress relieving.There are mounting holes for the master, return cylinders and holes for four columns.
2.1.2 Slides
Slider is made by ZG270-500 cast steel,annealing treatment after casting,stress relieving.The top of slider is connected with the master cylinder piston rod combined with the flange bolts.The downside of slide has positioning device,there are column holes processing on each four corners with guide sleeves.
2.1.3 Working Table
Working Table is made by ZG270-500 cast stee,annealing treatment after casting,stress relieving, working table has located with column holes, the plane is equipped with guide plates,its material is abrasive resistant material.
2.1.4 Column
Column material use 45 # forged steel, both ends of procedure has 45 º moment profile thread, close to the table there are column protection covers, guide sleeve material is made by ZQSn6-6-3.Columns are thermal refining,guiding parts quenching treatment at medium frequency,hardness:HRC45-52, oriented part rolling treatment.
Diameter 470mm.
2.1.5 Nuts
45 # forged steel nut material, with hole processing at 45 º thread profile moments, with round columns to match the threads to locking main body
2.2 Oil Cylinder
2.2.1 The master cylinders and return cylinder are plunger type,good quality seals inside fuel tank.Steel cylinder use 35# forged steel piece, plunger rods are 45 # steel forgings,surface quenching treatment, hardness is HRC45~52,circumcircle grinded, guiding sleeve materials is ZQSn6-6-3, one end of the plunger is plug into sliders. Three master cylinder piston diameters are Φ500,Φ880,Φ500. 
2.2.2 Moving working table push to pull cylinder is plunger cylinder, the cylinder material is 45 # forged steel, plunger material is 45 # forged steel, surface quenching treatment,hardness is HRC45~52,cylindrical grinded,one end of plunger rod is connected with moving table,guiding sleeve material is ZQSn6-6-3.
2.3 Moving Working Table
Moving working table is used for easy modes replacement and forging die moved, The material of moving table is ZG270-500 cast steel, table bear the weight of the die sets and working load, and transfer to the body table,under platform are equipped with the guide plate its material is 45 # forged steel, the quenching hardness is HRC42~52, the table moved back and forth is driven by two horizontal cylinders
3,Hydraulic control system
The hydraulic control system consists of cylinder,oil pump motor group,two-way cartridge valve,liquid-filled devices,pipeline,oil tanks and other components.With electric system to control cylinder to drive the slider to move, to complete a variety of process action.
3.1 oil pump motor group
main oil pump motor group: 9. each group consists of 2 sets high-pressure pumps & 1 set motor (200KW)
3.2 two-way cartridge valves
The Hydraulic system control valve block uses two-way cartridge valves, It has the advantages of simple structure,large flow capacity,anti-pollution ability,reliability,fast response,flexible control, etc.
Since the machine has a fast forging process requirements,the master cylinder to the hydraulic control system of relief loop adopted proportional control loop (fast forging valve) to meet the master cylinder pressure relief rapidly, reduce relief shock and noise.
3.3 fuel tank pipeline
The main fuel tank of The hydraulic control system is placed on the ground,fuel tank consists of the oil return tank and the absorption tank equipped with a separate hydraulic oil cooling and filtering system.The fuel tank is steel plate welded,with passive anti-rust treatment. The oil pump motor group is arranged at one side of the tank;some valve blocks and cooling,filtering motor pumps group is placed on the upper plane of the tank. oil pump motor group, the main fuel tank, cabinet separated with the host to form a clean, relatively independent space.
Hydraulic shock and vibration in the press hydraulic system is large,so the hydraulic system piping all joints should be sealed using a special axial flange connection,and set additional shockproof tube cards as requirement,set reasonable piping according to its technical characteristics, reduce energy loss, to prevent leakage.
The oil tank has a level display function if the oil level is too low,must fill the oil tank to the standard level.
3.4 The press filling loop normally adopted closed valve,and its main role is to provide the master cylinder suction oil, when the slider down quickly, due to the negative pressure chamber of the master cylinder, the filling valve opening,a lot of oil suction in the fuel tank, when the slider stops moving, filling valve closed,open filling the spool so that liquid-filled tank to drain the oil from the control slider backhaul.
3.5 The press hydraulic system should have a cooling filter, make sure the oil temperature below 50 ºC.
Hydraulic press oil temperature should be >10 ºC and <60 ºC. When the oil temperature is lower than 10 ºC, the press can not work; only after preheated to 10 ºC, can the press operate. when the oil temperature reaches up to 50 ºC,should open cooling water, cool down the oil. when oil temperature reaches up to 60 ºC should stop working to check,ensure the system working under allowed temperature range.
The hydraulic oil cooling and filtering are equipped with a separate circulation system which starts to circulate automatically after operation.
There is a large-capacity precision filter in the circulation filter system,with the audio alarm warning when the dirt of filter is blocked to indicate maintenance personnel to clean or replace the filter.
4,Electrical control system
   Three-phase five wire system AC power supply voltage is 380V, 50Hz; control circuit is AC 220V; pilot solenoid valve control power is AC 220V.
It is equipped With specialized electrical control cabinets, one main control cabinet, the electrical components used for driving (such as the power switch, air switch,AC contactor, control transformer, leakage protection) are housed inside the cabinet.inside the cabinet the light and the Ventilation facilities (air heat exchanger).
Main control cabinet is installed with the PLC(Germany SIMENSE),The Control panel is also set various buttons and joysticks.Master manipulator cabinet placed on the floor next to the press, easy manipulation and observation.
4.1 The operation of hydraulic can be manual, linkage,exchanged by the switch.
4.1.1 Manual operation: press the manual button there is a corresponding action. If you raise your finger, the action will stop.
4.1.2 Linkage action: action with manipulator.
4.2 Working modes: open die forging process
5,Lubrication System
5.1 It use lubrication pump with electric focus on program-controlled automatic lubrication system that can control the run time and pause time of the pump. 
5.2 Lubricated position are four column guide sleeves of slider, and the friction surfaces between the moving working table and fixed table
6,Safety System
6.1 Each spare parts of the hydraulic system are equipped with hydraulic valve for system overpressure protection.
6.2 There are security platform on the top of the press, fences and up and down escalators, easy to maintain.
6.3 Electronic control system is equipped with motor overloaded and short circuit protection.

ITEM	UNIT	ZDYJ-800	ZDYJ-1000	ZDYJ-1250	ZDYJ-1600	ZDYJ-2000	ZDYJ-2500	ZDYJ-3150	ZDYJ-3500	ZDYJ-4500	ZDYJ-6000
CAPACITY	KN	8000	10000	12500	16000	20000	25000	31500	35000	45000	60000
WORKING OIL PRESSURE	MPa	25	25	25	25	25	25	25	25	25	25
DAYLIGHT	mm	2500	2500	2500	3000	3000	3900	4000	4000	4500	6000
STROKE	mm	1300	1300	1300	1400	1600	1800	2000	2500	2500	2600
DISTANCE BETWEEN COLUMNS CENTER	mm	2200×1260	2200×1260	2200×1260	2900×1550	2950×1500	3400×1600	3500×1900	4500×2000	4350×2150	5200×2300
DIAMETER OF COLUMN	mm	280	280	320	330	400	470	500	520	580	690
DIMENSION OF SHIFTING TABLE	mm	3600×1300×300	3600×1300×300	3600×1300×300	4000×2000×300	4200×1600×300	5000×2000×350	6000×2000×350	6000×2200×400	7000×2400×400	9000×3400×400
STROKE OF SHIFTING TABLE	mm	2200	2200	2200	2500	2500	3000	4000	4400	4500	6000
CAPACITY OF RETURN	KN	1000	1500	1500	1700	1500	2000	2000	2500	4000	6500
WORKING POSITIONS OF SHIFTING TABLE		3	3	3	3	3	3	3	3	3	3
ECCENTRICITY DIMENSION OF FORGING	mm	120×80	120×80	150×75	150×75	150×100	150×100	150×120	200×150	200×150	200×150
GRADE NUMBERS OF CAPACITY		1	1	1	2	3	2	2	3	2	3
FIRST CAPACITY	KN	8000	10000	12500	10000	7000	15000	15000	15000	25000	20000
SECONDLY CAPACITY	KN				16000	14000	25000	31500	20000	45000	40000
THIRDLY CAPACITY	KN					21000			35000		60000
PRESSING SPEED AT APPROACH	mm/s	300	300	300	300	300	300	300	300	300	250
PRESSING SPEED AT FIRST CAPACITY	mm/s	74	66	60	67	195	114	137	170	126	190
PRESSING SPEED AT SECONDLY CAPACITY	mm/s				42	97	68	55	126	69	106
PRESSING SPEED AT THIRDLY CAPACITY	mm/s					65			72		53
RETURN SPEED	mm/s	300	300	300	300	300	300	300	300	300	250
SPEED OF SHIFTING TABLE	mm/s	200	200	200	200	200	200	200	200	180	150
ACCURACY OF SHIFTING TABLE MOVING	mm	±0.5	±0.5	±0.5	±0.5	±0.5	±0.5	±0.5	±0.5	±0.5	±0.5
DEGREE OF FORGING	times/m	60	60	60	60	45	45	45	45	30	25
CARRYING CAPACITY OF SHIFTING TABLE	T	20	20	20	25	35	40	50	60	80	100
SHIFTING TABLE HEIGHT ABOVE FLOOR LEVEL	mm	0	0	0	0	0	0	0	0	0	0
TOTAL POWER	KW	660	880	880	1320	1540	1760	2200	2860	3300	3960
WEIGHT OF PRESS(TOTAL)	T	160	180	200	230	290	320	440	480	760	1100
OVERALL HEIGHT ABOVE FLOOR LEVEL	mm	7800	8000	8100	8500	9000	10000	11000	12500	13500	15700