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COLD FORGING PRESSES FOR WASHER PRODUCTION

 

SERVO COLD FORGING PRESS MACHINE FOR STAMPING WHEEL NUTS AND WASHERS FROM WIRE AND ROD

The RCF series cold forging press is designed for cold stamping of wheel nuts and washers in sizes M16, M18, M20, M22, M24, M27 from wire and rod. The equipment set consists of a 3-position cold forging press with a servo drive, a press for flattening the workpiece and a cutting machine for cutting the workpiece from wire, interconnected by an automatic workpiece transfer system.

automatic press for stamping nuts and washers
Automatic press with a servo drive for stamping wheel nuts and washers from wire and rod with a working range of Ø15-50 mm, complete with full-automatic cutting and flattening machine (left).



Technical Specification of Precision Servo Driven Cold Heading Presses for Forging Nuts and Washers from Wire and Rod
Model Name RCF-330 RCF-530 RCF-345 RCF-545 RCF-363 RCF-563 RCF-380 RCF-580 RCF-3100 RCF-5100
Capacity KN 3000 4500 6300 8000 10000
Rated tonnage point (above B.D.C.) mm 7 8 10
Stroke mm 160 180 220 250
Speed (number of strokes per minute) SPM 45 40 35 30
Distance between the die plate and the slider in its lower position with the upper adjustment position mm 500 550 600 700
Slider Adjustment mm 25
Slider Area mm 800 × 700 1100 × 700 850 × 750 1150 × 750 900 × 800 1300 × 800 1000 × 850 1400 × 850 1000 × 850 1450 × 850
Bolster Area mm 900 × 830 1200 × 830 950 × 870 1250 × 870 1000 × 950 1400 × 950 1100 × 1050 1500 × 950 1100 × 1050 1550 × 1050
Dies Pitch mm 160 180 220 240 260
Punch Hole mm 100 120 140 150
Main Die Hole mm 130 150 180 200 220
Lower Knockout Stroke mm 50 60 80 100
Upper Knockout Stroke mm 35 40 45 50
Bolster Thikness mm 150 180 150 200 230 200 250 200 250
Bolster Surface Height mm 900 1000 1150 1100 1250 1200 1400 1200 1400
Main Motor Power kW 75 95 132 150 185 175 210
Required Air Pressure kg/sm2 5



Technical Specification of automatic cutting and flattening machine
Model Name RSD-200 RSD-300 RSD-400 RSD-600
Capacity KN 2000 3000 4000 6000
Rated tonnage point (above B.D.C.) mm 7 8 10
Stroke mm 150 180 200 220
Speed (number of strokes per minute) SPM 50 45 40 35
Slider Adjustment mm 12 15
Maximum Cutting Diameter mm 20-30 20-36 25-42 30-50
Cutting Lenght mm 15-35 15-40 20-40 25-50
Minimum Product Thikness mm 6 8 10
Maximum Product Diameter mm 42 52 63 75
Main Motor Power kW 20 30 45 55
Required Air Pressure kg/sm2 5


Technical Specification of Automatic Workpiece Transfer Mechanism with Servo Drive
Model Name   RTF-150 RTF-200 RTF-250
Feed Stroke mm 120-180 150-220 200-280
Clamp Stroke (one side) mm 20-40 30-70 30-80
Clamp Arm inner Width mm 130-160 180-240 200-250
Clamp maximum Length mm 800 1200 1400
Size of Feed Line mm 35 × 35 60 × 50 70 × 60
automatic workpiece transfer system
Automatic Workpiece Transfer Mechanism with Servo Drive



Design Features of a Press with a Servo Drive

The equipment is a CNC mechanical press designed for the production of wheel nuts and washers through cold forging from wire and rod.

Its operation principle is based on transforming the rotational motion of the drive into the reciprocating motion of the slider.

The working part of the cold forging press is a stamp consisting of two halves: the upper movable (punch) and the lower fixed (die). The die is attached to the press table, while the punch is affixed to the press slide.

The press machine includes an automatic mechanism for feeding metal into the working area, a calibration device for straightening the rod workpiece, and a conveyor for removing metal shavings from beneath the working area.

The main engine of the press machine is equipped with oil cooling, and the cold heading press features a centralized lubricant supply system.

For cold forging washers and nuts, the press is equipped with a Kingservo servo drive from Taiwan. In comparison with traditional knuckle joint cold forging presses, this design decelerates the ram at the bottom dead center, enhancing forming accuracy. The contact speed of the stamp is low, extending the service life of both the stamps and the press, and reducing noise at the point of contact. The servo drive with negative feedback control ensures precise control of motion parameters, with key characteristics including motor dynamics, motion uniformity, and energy efficiency. This servo drive design is highly optimal for forging operations, cutting thick sheets, and cold forming.

The operator controls the press through a touch screen, adjusting all production parameters, including productivity, die equipment height, feed length, and others.

The press body, designed like a box, offers excellent rigidity and improved bottom dead center accuracy. Holes on the sides facilitate the convenient installation of additional equipment for automation and protection, according to customer requirements.

The cold forging press drive is completely concealed inside the housing. The press ram is driven by a servo drive, gears, and an eccentric shaft, connected by toggle joints.

A safety brake is incorporated. If no operation occurs within 30 seconds after the main motor starts operating, the safety brake automatically cuts off the power supply to the main motor, stopping the mechanism instantly. The safety brake design employs dry friction pads.

The press's safety system adheres to the highest press machine safety standards, ensuring worker comfort and safety. It includes photoelectric sensors that automatically shut off the equipment when foreign objects enter the work area. Additionally, the press safety system features emergency stop devices, motor overload protection, prevention of excessively low rotation speeds, and error monitoring.


A typical set of equipment for the production of truck wheel nuts

  • 3-position automatic servo-driven press for cold forging of products.
  • Continuous Die set with programmable progressive step and quick change system.
  • Mechanism with servo drive for automatic workpieces transfer.
  • Cutting and flattening press machine.
  • Straightening and unwinding device for wire..


Technological process for manufacturing a wheel washer by stamping from wire or rod

The coil of wire is installed on the unwinder. The wire is unwinded and fed to the wire straightening device. The feed rate is controlled by the inverter. The wire straightening device guides the wire with steel rolls in the vertical and horizontal plane. Next, the feed mechanism directs the end of the wire to a cutting machine to cut the wire to length and flatten it using a hammer.

After this, the flattened workpiece is moved using a transport mechanism or conveyor into the vibrating hopper of a 3-position cold forging press.

Cutting off a workpiece
Cutting off a workpiece
workpiece flattening
Workpiece flattening
1st position (preliminary deformation)
1st position (preliminary deformation)
2nd position (forming a hole)
2nd position (forming a hole)
3rd position (final formation)
3rd position (final formation)


From the vibrating hopper, the workpiece is moved along a guide to the cold forging zone. An automatic workpiece transfer mechanism (grab transfer) with a servo drive alternately moves the workpiece to forging positions 1, 2 and 3.

In the first forging position, preliminary deformation of the wheel nut (washer) is performed. In the second position, the piercing punch forms the hole for the future product. In the third position, the product becomes marketable. Then the products are unloaded into factory containers.


STAMPING OF PRODUCTS FROM WIRE AND ROD - 100% WASTE-FREE PRODUCTION


ECONOMICAL USE OF RAW MATERIALS

Upsetting a washer from a rod
Upsetting a washer from a rod,
100% waste-free production
Штамповка шайбы из листовой стали
Stamping washer from sheet steel,
metal scrap and shavings 50%




Possibility of re-adjusting cold forging presses for upsetting products from rods (coils of wire) and from steel sheets

Cold forging presses are ideal for upsetting washers and various flat products. A special feature of this equipment is the ability to plant flat-shaped products from metal rods, as well as from sheet metal.

The dies are made of high quality metal SKD-11 and S45C.

Progressive Dies
Continuous Die Set
Upsetting from the rod
Upsetting from the Rod
Upsetting from sheet steel
Upsetting from Sheet Steel
Upsetting from sheet steel
Upsetting from Sheet Steel


The possibility of lateral movement (left/right) of the workpiece feed mechanism allows you to punch holes of up to five pieces across the width of the strip. This allows for the most efficient use of the workpiece metal and minimizes production waste when stamping washers from sheet steel.



Photo gallery

Cold forging of a washer made of wires

The wire bundle is installed on the straightening-unwinding device
The wire bundle is installed on the straightening-unwinding device
unwinding the coil and straightening the wire
The coil is automatically unwinded and the wire is guided by horizontal and vertical steel rollers
Horizontal straightening rollers
Horizontal straightening rollers
Vertical straightening rollers
Vertical straightening rollers
The feed mechanism guides the end of the wire into the cutting machine to cut and flatten the workpiece
The feed mechanism guides the end of the wire into the cutting machine to cut and flatten the workpiece
Area for feeding the workpiece into the cutting machine
Area for feeding the workpiece into the cutting machine
Cutting and flattening the workpiece
Cutting and flattening the workpiece
Automatic workpiece transfer system with servo drive alternately moves the workpiece to the forging positions
Automatic workpiece transfer system with servo drive alternately moves the workpiece to the forging positions
washer formation at forging positions
Washer formation at forging positions.


Cold stamping of metal plates for fastening barrier-type road fences

Touch screen
Touch screen for setting production parameters, stroke counting, die height, loading and control of the press
SICK C2000 safety system
The SICK C2000 safety system automatically turns off the equipment if foreign objects enter the work area
Automatic feeding mechanism
Automatic feeding mechanism The workpiece feed speed is controlled by an inverter.
press operating modes
Press operating modes: manual, one-pass, automatic. The mode of free feeding of the workpiece is available when the crimping rollers are unclamped.
Calibration device.
Calibration device.
Crimping rollers
Crimping rollers, in addition to feeding the workpiece, perform the function of guiding the metal and eliminating bends.
Pneumatic mechanism
Pneumatic mechanism
Servo drive
Servo drive. Reversible device for the main motor. Centralized lubricant supply system.
changing a stamp
The process of changing a stamp is simple, convenient and quickly.
metal plates for fastening barrier-type road fences
Finished products - metal plates for fastening barrier-type road fences



TYPES OF MANUFACTURED PRODUCTS

High-strength washers

GOST 22355-77Washer, high strength
GOST 22355-77
Washer, high strength
DIN 6916 (DIN EN 14399-6)Washer, high strength
DIN 6916 (DIN EN 14399-6)
Washer, high strength
GOST Р 52646-2006Washer, high strength
GOST Р 52646-2006
Washer, high strength


Small diameter fasteners (micro fasteners)

DIN 127 A2Spring washer (Grover), a small-diameter steel
DIN 127 A2
Spring washer (Grover), a small-diameter steel
DIN 125 A2Washer, flat, small diameter steel
DIN 125 A2
Washer, flat, small
diameter steel
DIN 9021 A2Reinforced washer (body), small diameter steel
DIN 9021 A2
Reinforced washer (body), small diameter steel
DIN 6798 A2Lock washer with external teeth, a small-diameter steel
DIN 6798 A2
Lock washer with external teeth, a small-diameter steel


Stainless steel washers

DIN 125 A2Washer, flat, stainless steel
DIN 125 A2
Washer, flat, stainless steel
DIN 7980 A2Spring washer (Grover)
DIN 7980 A2
Spring washer (Grover)
DIN 9021 A2Reinforced washer (body)
DIN 9021 A2
Reinforced washer (body)
DIN 6798 A2Lock washer with external teeth, stainless
DIN 6798 A2
Lock washer with external teeth, stainless


Retaining rings

DIN 471(GOST 13942-86)Retaining ring for shaft
DIN 471(GOST 13942-86)
Retaining ring for shaft
DIN 472 GOST 13943Lock ring for holes
DIN 472 GOST 13943
Lock ring for holes


Washers are not included in other sections

GOST 11371-81 (DIN 125)GOST 6958-78 (DIN 9021), reinforced
Плоская
Flat washer GOST 11371-81 (DIN 125), GOST 6958-78 (DIN 9021), reinforced
GOST 6402-70 (DIN 7980)Spring washer (Grover). Normal, heavy, light
GOST 6402-70 (DIN 7980)
Spring washer (Grover).
Normal, heavy, light
DIN 6799 (GOST 11648)Washer Lock quick
DIN 6799 (GOST 11648)
Washer
Lock quick
Washer roofing EPDM with rubber shimWasher roofing EPDM with rubber shim
Washer roofing
EPDM with
rubber shim
DIN 6798 A (GOST 10463)Lock washer with notches (spring)
DIN 6798 A (GOST 10463)
Lock washer with
notches (spring)
DIN 6797Lock washers
DIN 6797
Lock
washers
DIN 2093 (GOST 3057)Spring Dished
DIN 2093 (GOST 3057)
Spring
Dished
DIN 7993 Split Washer
DIN 7993
Split
Washer
DIN 463 Lock crow Washer
DIN 463
Lock crow
Washer
DIN 25201Lock Washer
DIN 25201
Lock
Washer



EQUIPMENT FOR PRODUCTION OF SPRING WASHERS (GROVER)


Detailed information about equipment for the production of spring washers (equipment for the production of growers) is available on the page EQUIPMENT FOR PRODUCTION OF SPRING WASHERS (GROVER)



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