High-efficientforging- and press equipment

produced at OAO Tyazhpressmash (Russia)

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Key Products

Forging- and press equipment; Oil/gas production tools; Primary metal production (steel-, iron- and non-ferrous castings, open-die and closed-die formed parts); Products for municipal services; Light aircrafts (2-seaters); Miscellaneous products (various machine parts and units).

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Number of employees at OAO Tyazhpressmash: 3500

Main plant production area in Ryazan is about 400 000 m2

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Our design team consists of 130 engineers

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Machinery for the following manufacturing processes

Hot die forging; Cold die forging; Radial swaging; Sheet presswork; Rotary forming; Elbow bend and T-pipe production; Super-hard materials including synthetic diamonds

sintering; Refractory materials briquetting; Non-metal materials briquetting; and many other production processes.

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Technological capacities ofour production facilities

Every our product is subject to a trial on a test stand

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Maximum weight of single components processed, ton

125

Maximum weight of the heaviest hydraulic press manufactured at our facilities, ton

1550

Maximum force of presses manufactures at our facilities, MN

63,0

Pictures of the technological equipment employed at primary metal production facilities of OAO

Tyazhpressmash

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Forging operation on a Radial Forging MachineModel ВВ4032Ц

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Forging schemes

Fig.1 Scheme of a forging operation performed between two dies on a press

Fig. 2 Scheme of a forging operation performed between four dies on a radial forging machine

Fig. 1

Fig. 2

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Advantages and limitations of hydraulic forging presses as compared to radial forging machines

Advantages Limitations

Higher quality of forged metal

Capability to forge ingots of higher weights and larger dimensions

Hydraulic forging press is a multipurpose machine capable to perform a variety of forging operations. Radial forging machine is capable to perform mainly drawing operations.

Commonly available machine produced by many machine manufacturers. Better affordable for the customers.

Hydraulic forging presses price is lower as compared to radial forging machine price.

Lower accuracy of forged parts

Lower material utilization ratio

Lower production output

Forging operation to produce certain products commonly involves several forging passes and re-heatings.

Higher gas consumption.

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Kinematics of dies movements in a four-die forging device

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Ingot forging in a Four-Die Forging Device installed on a 25 MN forging press

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Forged parts produced in a four-die forging device installed on a 25 MN press

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Sequence of an ingot cross-section changes during successive forging passes:

1 – ingot cross-section;2 – dies;3, 4 – component cross-sections at intermediate forging passes;5 – component cross-section after finishing operation.

- forging operation involving metal spreading between the dies

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Forging techniques described above offer the following benefits:

Elimination of cast metal structure defects; Reduced thickness of defect metal surface layer

of a forged part; Drawing ratio up 9 at a single heating of ingot; High-accuracy forged parts having a surface

quality similar to the surface quality of rolled stock.

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Main advantages of Four-Die Forging Devices

A 2-times higher average forging output as compared to two-die forging technique; 10 – 12 per cent increased metal yield; 2.5 times reduced forging tolerances; Reduced re-heating requirements and reduced gas consumption; No need to procure specialized and expensive forging machinery (radial forging machines).

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First industrial Four-Die Forging Device supplied to a Russian customer

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First industrial Four-Die Forging Device supplied to a PRC customer

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Four-Die Forging Device supplied to a customer in Germany

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Computer simulation of an ingot forging operation performed in a four-die forging

device

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Supplies of four-die forging devices

TOTALLY: 15 devices.

CountryPress force, MN

10.0 12.0 12.5 16.0 20.0 25.0 30.0 45.0

Germany 1 No.

Russia 4 Nos. 3 Nos.

PRC 1 No. 1 No. 1No. 1 No. 1 No. 2 Nos. 1 No.

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New applications of Four-Die Forging Devices

Production of forged stepped parts starting from initial thin-walled pipe stock;

Production of thick-walled forged pipes of alloyed steel grades.

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Pipe forging in a Four-Die Forging Device

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Stepped pipes

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Pipe forging on a mandrel in a Four-Die Forging Device

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Innovating method of pipe production

Pipe forging on a short mandrel in a four-die forging device installed on a press

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Pipe forging on a short mandrel in a Four-Die Forging Device installed on a press

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Forged pipe

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Innovating technological process

Pipe forging on a short mandrel in a four-die forging deviceinstalled on a press offers combined advantages of forgingon a press and on a radial forging machines:

High quality of forged metal High production output High accuracy of forged parts Increased lengths and diameters of forged parts High metal utilization ratio Employment of multi-purpose forging equipment Reduced energy consumption

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Pipe forging on a short mandrel in a Four-Die Forging Device installed on a press

Increased production range of forged parts of variousoutside diameters, wall thickness and weights ascompared to radial forging machines of equivalentcapacity

Production of forged pipes of larger diameters andweights as compared to conventionally used productiontechniques employed on forging presses in capacities of60МN, 120МN and higher.

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Patent protection of our innovative solutions

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Considering a high inventive level of a four-die forging device designwe have filed patent applications on the device and obtainedrespective RF patents (totally 10 patents); patent holder of all theinventions is OAO Tyazhpressmash.

The device is patented in the European Patent Office countries(Germany, UK, Italy, Spain, France), in Ukraine, Kazakhstan andChina; a patent procedure is initiated in Korea.

Importers of our forging-and press equipment

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Operation of Automatic Hot Forming Line for bearing rings production

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Typical technology of semi-finished bearing rings production

UpsettingPiercing and separation of

rings

Cut-off 1st Station 2nd Station 3d Station 4th Station

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Technical specifications of Hot Forming Production Lines

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Production line Models TPM30 TPM50XL TPM70 Production capabilities: Weight of initial component g 50 – 700 140 - 2000 300 - 4600 Maximum size of upset product mm 67 104 145 Initial part diameter mm 19 - 40 25 - 55 36 - 75 Initial part length mm 20 - 72 25 - 110 44 - 135 Technical specifications :Upsetting slide strokes per minute(adjustable)

85 - 120 60 - 100 50 - 70

Hot Former rated force kN 2500 8000 15000 Tools:Number of working stations 3 4 4 Slide stroke mm 160 240 320 Dies diameter : - 1st station mm 125 160 (185) 220 - 2nd station mm 150 215 290 - 3d station mm 125 215 290 - 4th station mm - 200 (215) 270 Stroke:- of slide mm 160 240 320 - of die kick-outs mm 70 90 130 - of punch kick-outs mm 26 48 55

Kinematic analysis of the tools

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Automatic Forming Line for bearings rings production installed in Shanghai (PRC)

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Hot Former Model TPM50XL installation in South Korea

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First Automatic Production Line for deep well sucker rod production supplied to PRC

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The Production Line incorporates the following features:

Control of the forming force, heating temperature and initial bar straightness;Transfer means and bar ends induction heating facilities

to process long initial components;Components marking outside the die working zone;Die heating facilities;Tool lubrication facilities;Dies lubrication facilities;Hot Former lubrication systemCooling system;Machine lubrication oil/tool graphite lubricant separation

and other technical solutions.

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Production line in operation

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Automatic Production System for sleeve-type components production

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Typical sleeve-type products

Products weight: up to 200 kgProduct length: up to1200 mm

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Sleeve-type product forming

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Manufacturing operations

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1st station 2nd station

3d station

Main advantages of the Automatic Production System АКП0950.31

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high technological capacities; high uniformity of components heating along the cross-section plane; minimized variation of wall thickness; high accuracy of forged products; minimized allowance for finish machining; high metal utilization ratio; low rejection rate due to full automation of production process; high production output; minimized number of servicing personnel.

Samples of railway fasteners

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Hot Former Line Model Л316for bolt production

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MAIN TECHNICALA SPECIFICATIONSDIAMETER OF UNDERHEAD PORTION OF BOLT, ММ 22

BOLT UNDERHEAD PPORTION LENGTH, ММ: MAXIMUMMINIMUM

75195

LENGTH OF BOLT THREADED PORTION, ММ: MINIMUMMAXIMUM

4080

INITIAL COMPONENT DIAMETER, ММ 21.7

INITIAL COMPONENT LENGTH, ММ MINIMUMMAXIMUM

130250

INITIAL MATERIAL ULTIMATE STRENGTH, KGF/MM2 <50

CALCULATED PRODUCTION OUTPUT ON THREE SHIFTS A DAY BASIS AT 0.7 EQUIPMENT UTILIZATION FACTOR, PCS/YEAR

14300000

CALCULATED OUTPUT PER MINUTE, PCS/MIN 58

NUMBER OF EQUIPMENT UNITS INSTALLED, NOS. 14

TOTAL INSTALLED POWER OF PRODUCTION LINE ELECTRIC MOTORS, KW 214.6

RATED CAPACITY OF INDUCTION HEATER, KW 500

SUPPLY MAINS VOLTAGE, V 380

SUPPLY MAINS FREQUENCY, HZ 50

INDUCTION HEATER CURRENT FREQUENCY, HZ 4000

SERVICING PERSONNELL, PERSONS 5

INITIAL MATERIAL (COIL MATERIAL WEIGHT), KG UP TO 2100

PRODUCTION LINE OVERALL DIMENSIONS IN PLAN VIEW, MMLENGTH WIDTH

4084510500

EQUIPMENT HEIGHT ABOVE FLOOR LEVEL, MM 5050

Hot Former Line Model Л316 for bolt production in operation

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Automatic Production System АКА0334.031

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Технические характеристикиHot Former rated force, kN 2500Size of produced nut,

minimum M200maximum M36

Maximum diameter of formed product, mm 66Maximum size across flats, mm 55Initial bar diameter, mm 22…40Initial slug weight, g 50…700Slide strokes per minute 70…100Slide stroke, mm 160Number of electric motor 8Main drive power, kW 56Overall dimensions, mm

left-to-right 19000front-to-back 6100

Height above floor level(w/o jib crane), mm 2330(complete with jib crane), mm 3843

Compressed air consumption, m3/h 3Compressed air pressure, MPa 0,5

Automatic Production System АКА0334.031 in operation

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Machinery for rail clips production

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4-, 5- and 6-station Cold Former ModelsАБ0924А, АА9035 and А0937

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Cold Former АБ0924А in operation

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63MN Hydraulic Press for T-pipe production

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Our benefits

60-years’ experience in machinery production fordomestic and foreign markets.

Experienced professionals highly skilled in metal formingtechnology and in building hydraulic and mechanicalforging machines and automatic production lines.

Creative partnership relations with technical universitiesand customers.

State-of-art computer-aided design tools for simulationand development jobs for machines and technologies.

In-house try-out base for technology development. In-house versatile production facilities. One-package supply of technology, tools and machines. Prompt after-sales servicing of supplied equipment.

Our priority area:

Development of technology solutions to meet our

customer’s requirements in the metal forming sector

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