Product Program / Precision Forging

PTS is a new tool system developed for horizontal press machines and designed to substitute the standard tool system. PTS consists of a housing that is clamped directly to the press machine. The die set is preassembled before being inserted into PTS, and then a top lid is mounted at the front of PTS while providing axial prestressing to the die set. The forging die itself is radially prestressed by a high-strength stripwound container.

PTS is offering additional strength and controlled prestressing of the die set compared to a standard tool system and is offering a unique capability to improve the service life of both the forming die and the prestressing tool system itself. Specific calculations are required in each case.

PTS is with design modifications applicable for cold forging processes running at Hatebur as well as Sakamura, National, Nedschroef, and other horizontal formers.

 Catalog - Prestressing Tool System / H-Type

PTS is a new tool system that can be customized to the vertical press machines and is essentially designed to substitute the standard tool system. In short, PTS is offering additional strength and controlled prestressing of the die set compared to a standard tool system. Consequently, PTS would offer unique possibilities for improving the service life of the forming die and high reusability of the prestressing tool system itself.

Depending on the type of press and machine maker, PTS consists of a housing that is clamped directly to the press table. The die set may be preassembled before being mounted into the PTS assembly. Radial prestressing is provided by the high-strength stripwound container while controlled axial prestressing of the die stack is ensured with a special-designed top lid.

The graphic illustration below is a principal layout of PTS, which originally was developed for the horizontal press machines. An implementation of PTS for a vertical press would be subject to customization in each case including both analytical calculations and a customized tool design.

 Catalog - Prestressing Tool System / V-Type

High-strength prestressing container made by the stripwinding technique. The inner core of the container is of hardened tool steel, and the steel strip material can withstand up to 200° C for the SC 200 and up to 400° C for the SC 400. The outer steel ring is assembled to the stripwound section by heat shrinkage.

The SC 200 and SC 400 containers have about double the strength compared to a standard compression ring and offer a unique capability to optimize the radial prestressing of the forming die while remaining in a fully elastic state. This unique product feature offers two important merits: Higher service life of the forming die, and a prestressing tool that can be reused numerous times at full capacity. Specific calculations are required in each case.

The SC 200 container is mostly applied for cold forging and comparable cold work applications involving high or even extreme tool loads.

The SC 400 container is mostly applied for warm forging and comparable heated applications involving high or even extreme tool loads.

The SC 200 and SC 400 can both be used on all types of press machines. Minimum diameter of both containers can be approx. ø50 mm.


 

 Catalog - SC 200 / SC 400

High-strength and high-stiffness prestressing container made by the stripwinding technique. The inner core of the container is of tungsten carbide, and the steel strip material can withstand up to 200° C for the SC 200+ and up to 400° C for the SC 400+. The outer steel ring is assembled to the stripwound section by heat shrinkage.

The SC 200+ and SC 400+ containers have about double the strength and double stiffness compared to a standard compression ring and offer a unique capability to optimize the radial prestressing while reducing the physical deflection (i.e. strain) of the forming die under maximum process load. Furthermore, the SC 200+ and SC 400+ would stay in a fully elastic state during the press cycle. This unique product feature offers three important merits: Higher service life of the forming die, improved measure for controlling the part tolerance, and a prestressing tool that can be reused numerous times at full capacity. Specific calculations are required in each case.

The SC 200+ container is mostly applied for cold forging and comparable cold work applications involving high or even extreme tool loads.

The SC 400+ container is mostly applied for cold-heated and warm forming applications involving high or even extreme tool loads.

Both the SC 200+ and SC 400+ can be used on all types of press machines. Minimum diameter of both containers can be approx. ø60 mm.


 

 Catalog - SC 200+ / SC 400+

High-strength prestressing container made by the stripwinding technique. The inner core of the container is of hardened tool steel or tungsten carbide, and the steel strip material can withstand up to 200° C or 400° C depending on the choice of strip material. The outer steel ring is assembled to the stripwound section by heat shrinkage. The pressure pad and bottom ring screw for axial prestressing are both made of hardened tool steel.

The SC AXI-FIT container has about double the strength compared to a standard compression ring and offers a unique capability to optimize both the radial and axial prestressing of the forming die while remaining in a fully elastic state. Axial prestressing is applied by tightening the bottom ring screw while having the forming die under static pressure. This unique product feature offers three important merits: Higher service life of the forming die, preventing horizontal cracking or die split by axial prestressing, and a prestressing tool that can be reused numerous times at full capacity. Improved part tolerance can also be achieved if the inner core of the SC AXI-FIT container is made of tungsten carbide/i.e. E+ type. Specific calculations are required in each case.

The SC AXI-FIT container is mostly applied for cold and warm forming applications involving high or even extreme tool loads. The prestressing tool can be used on all types of press machines. Minimum diameter of the SC AXI-FIT container can be approx. ø50 mm.
 

 Catalog - SC AXI-FIT

A double ring is a prestressing tool made of two hardened steel rings that are assembled by press fitting. A double ring is about 40% stronger than a 1-ring system but has a much lower strength compared to a stripwound container. The stiffness is comparable with the SC 200 container as the ring is made of tool steel, and the inner and the outer rings are hardened to 54 HRc and 46 HRc, respectively. The optimal interface between the outer and inner ring is determined by analytical calculations and assembled by press fitting. The inner surface of the double ring is conical for example by 1° and ground for ensuring a smooth assembly of the forming die and extension of the service life. Specific calculations are required in each case.

The purpose of a double ring is the same as a stripwound container and can in general be applied for both cold, warm, and hot working applications. A double ring is cheaper than a stripwound container but it is at the expense of reduced strength capability, and consequently a shorter service life of both the forming die and the double ring itself. Minimum diameter of a double ring can be approx. ø50 mm.

 Catalog - Double Ring

Most applications can be addressed effectively with a standard stripwound container design, for example SC 200 for a high-strength solution, or an SC E+ for a prestressing tool system offering both strength, stiffness, and durability (i.e. extended reusability of the prestressing tool). However, in some cases, we need to work out special container designs that fit the specific frame conditions of a customer’s press equipment. In such cases, we devote additional effort to understanding these special conditions and prepare our sketch proposal and quotation accordingly. Specific calculations are required in each case.

Example of a special-designed stripwound container solution:

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