FEATURE ON PRESSES AND COIL HANDLING

Large order for rail wheel production line

India-based Ramkrishna Titagarh Rail Wheels has placed an order for a wheel roller, two forging presses, automation, dies, a rotary hearth furnace and heat treatment, from Schuler and Andritz Metals. Like Schuler, Andritz Metals is part of the international Andritz technology group. Schuler says the order is in the upper double-digit million euro range

Ramkrishna Titagarh Rail Wheels is a joint venture between one of the largest suppliers of forged parts in India and the nation’s biggest manufacturer of railroad wagons in the private sector. The world’s most populous country plans to invest over $700bn in its rail network over the next few years.

“Schuler has already proven its expertise in the manufacture of railroad wheels with numerous production lines installed on the Asian continent,” says Naresh Jalan, managing director of Ramkrishna Forgings. “It was important for us to select a supplier whose equipment stands for high quality.”

Christian Palm, director hydraulic presses at Schuler, adds: “Forged railroad wheels are best at handling the extreme stresses of heavy acceleration and deceleration. We’re pleased to help take rail transportation in India to the next level with this production line.”

The forming of rail wheels takes place in four steps before they enter machining. First, a 10,000 ton hydraulic forging press produces a disc-shaped pre-form from a heated billet in two stages, receiving its final diameter in a wheel roller. Then, the second 5,000-ton press calibrates the rolled-out wheel before axial offsetting and piercing of the hub.
For further information www.schulergroup.com

New Rhodes Interform contractraisesthe roof

Rhodes Interform, a UK metal-forming machinery specialist, has secured a multi-million-pound contract to manufacture and supply a new mechanical punch press for Zentia, which specialises in complete ceiling solutions at its facilities in Gateshead.

The Rhodes DS2-315 geared press is a double-sided 315 tonne mechanical press, designed with a two-point suspension that allows for a larger working bed area, even distribution of nominal tonnage, and the accommodation of any offset loading. Installation will take place 2024. The entire process, including the design, manufacture, and installation of the press, will be handled by engineers at Rhodes Interform in Wakefield, including the removal of the press currently at the premises in Gateshead.

Mark Ridgway OBE, CEO of Group Rhodes states: ‘’It’s a privilege to supply Zentia with another high-specification metal-forming solution. As a market leader of complete ceiling solutions, Zentia requires the production speed and accuracy that the Rhodes DS2 mechanical press can provide.”

Neil Hunter, engineering and improvement manager at Zentia,adds: “The existing Rhodes press has been in service for 30 years and punched in excess of 300 million square metres of ceiling tile in this time. We’re looking forward to receiving the new increased tonnage press.”

Rhodes Interform is a division of Group Rhodes. Soon to be celebrating its 200th anniversary, the company offers a wide range of hot and cold-forming technologies for specialist metal-forming applications across several sectors. In addition, the company’s composite machinery produces structural components for the aerospace and automotive sectors.
For further information www.grouprhodes.co.uk

NIBE increases capacity with new press line

Heat pump manufacturer NIBE plans to increase the production of water heater components at its Markaryd, Sweden facility following the order for a new press line solution from AP&T.

“The demand for energy-efficient systems for heating and hot water production is growing steadily all over the world, and we continue to see a strong demand for our products,” says Henrik Broström, production technical group manager for sheet metal and welding at NIBE Energy Systems.“We’re now investing in new manufacturing capacity to future-proof the volumes we will need. The new production line from AP&T will manufacture stainless steel water heater ends and be an important complement to our existing lines.”

Stefan Persson, project manager at NIBE Energy Systems, adds: “In addition to manufacturing more units, the new line also ensures a stable production process with high repeat accuracy and availability.”

Together, NIBE and AP&T discussed and evaluated a number of different options before the final concept took shape.

“Our ambition was to develop a process solution optimised for NIBE’s specific needs and conditions that provides clear customer values,” explains Dan Barvö, key account manager at AP&T.“The line needed to be energy efficient, take up little floor space and be able to perform several steps with a few machines and tools.”

In the autumn of 2022, AP&T presented a fully developed proposal that met all of NIBE’s needs: a compact, energy-efficient, fully automated production line with a 500 tonne press for deep drawing, a smaller modular press, linear robots and tooling. Line commissioning will take place in 2024.
For further information www.aptgroup.com

Hydraulic presses suit engineering workshops

Machine Mart says that its range of Clarke Hydraulic Presses are ideal for engineering workshops. Eight models are available with pressing capacity ranging from 4 to 50 tonnes.

The best-selling Clarke CSA10BB 10 tonne hydraulic bench press is first choice when users need to tackle smaller pressing jobs, such as repairing small motors or removing and installing gears or bearings. Simple to use and effective, the Clarke CSA10BB requires minimal effort from the user to achieve fast, accurate pressing operations. The press comes with a hydraulic pump, ram with pressure gauge and connecting house. A seven-piece adaptor kit is available separately.

Moving up in capacity, the Clarke CSA20F 20 tonne hydraulic press relies on its heavy-duty welded-frame construction. According to Machine Mart, this press has smooth hydraulic action that ensures the positive and precise application of power to the workpiece for greater control and accuracy.Its 20 tonne capacity and 189mm ram travel also work together to make the CSA20F suitable for larger workpieces.

At the top end of the range is the Clarke CSA50 FPB 50 tonne hydraulic floor press. This standing shop press is suited to professional workshops and comes fitted with a large pressure gauge thatfacilitates accurate and easy reading when applying pressure. Smooth hydraulic action again ensures positive and precise power application, while the model also features both hand and foot operation, as well as a ratchet winch for adjusting the bed height. The CSA50 comes complete with hydraulic pump, ram, hoses, pressure gauge and V blocks. A protective polycarbonate screen is available to buy separately.
For further information www.machinemart.co.uk

Striking a hammer blow for metal recycling

Footprint Tools, a UK manufacturer of traditional hand tools, is at the heart of a research project that could see Sheffield spark a recycling revolution in industrial forging. The move has the potential to unlock a step-change in the manufacture of safety-critical components for the aerospace, defence and energy sectors using machining waste and state-of-the-art linear hammer technology.

The Sheffield-based business with 12 employees and two robots can trace its roots back to the 1760s, but has its eyes fixed firmly on the future. Footprint Tools recently unveiled the latest addition to its Admiral Works shopfloor: a £1.4m state-of-the-art Schuler precision linear forge, the only one of its kind in the UK and one of only three in Europe.

As the centrepiece of an R&D partnership between the small family firm and two research institutions – the Henry Royce Institute (Royce) and the University of Strathclyde’s Advanced Forming Research Centre (AFRC), part of the National Manufacturing Institute Scotland Group – the equipment will help consolidate Sheffield and the UK’s lead in advanced forging manufacture.

Following a packed gathering of the AFRC’s Forging and Forming Forum, where the R&D venture was announced, Royce Professor Martin Jackson said he was delighted that the servo technology hammer, initially destined for Manchester, had found a home in Sheffield, the hub of the UK’s forging and forming industry: “This raises forging technology to a completely new level. Our job at Royce and the AFRC is to take the knowledge we unlock from this R&D collaboration and roll it out to forging companies across the country, especially in the use of recycled machining waste such as titanium.”
For further information www.bit.ly/44R55PL