DIEFORMER

Type MP
A TRADITION OF PROGRESS

The Closed-Die Forging Division of SMS group with and without flash, made from very diversely alloyed
the traditional name Eumuco Hasenclever is able to aluminium or steel grades, as well as ­forming pro-
look back on a long tradition of press manufacture cesses ranging from hot to warm.
in which important developments have led from the
classic closed-die forging press to today’s automatic The automated DIEFORMER can be operated both
forming system. in intermittent and continuous mode, depending on
the requirements in hand or the part to be produced.
Our modern DIEFORMER stands out through its
versatility in handling the most varied forgings with

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3
STRUCTURAL DESIGN AND
FUNCTIONAL PRINCIPLE

(1) Frame
For the split tie-rod design, the SMS group attaches (8) Ram adjustment system
particular importance to a solid frame construction The ram adjustment system allows the height of
optimised using FEM computations. the die space to be adjusted in order to set up the
forging dies and compensate temperature differ-
(2) Ram / (3) Pitman ences or die wear.
The press ram is driven by two solid steel pitman The stroke position of the ram is adjusted by
shafts. These compact components with large means of a motor and worm gear and is held by
bearing bushes transmit the press forces in a separate clamps. The adjusting screw has been
straight line, without any edge pressure, from the designed for self-locking.
eccentric shaft via the wrist pin to the ram. Even The ram adjustment system can be actuated by
eccentric forging forces occurring during the forg- pressing a button on the control desk of the ma-
ing process can be transmitted. chine without interrupting the automatic operating
sequence.
(4) Ram guide system
When designing the DIEFORMER, we pay particu- Backgear / Herringbone gearing
lar attention to precise and long guidance of the Depending on the required forming energy, DIE-
ram in heat-resistant diagonal guides with nitrided FORMERS can be supplied with or without back-
guide ledges. gear. The drive torque is transmitted from the back-
gear to the flywheel by means of a herringbone
(5) Clutch / (6) brake system gear pair. This type of gearing ensures smooth
A fail-safe clutch/brake system ensures short running.
response times. Clutch and brake are mounted
directly on the eccentric shaft and thus protect the (9) Upper and lower (10) ejectors
press directly against overloading. The wet clutch/ DIEFORMERS are equipped with hydraulically
brake system is controlled electro-hydraulically and driven ejectors. These systems contribute signifi-
designed for fully automatic operation for short cantly to the process stability, particularly on fully
cycle times. For ease of maintenance, clutch and automatic forming presses.
brake are arranged separately on the flywheel side The ejectors have to transfer the workpiece to the
and on the opposite side of the press. The flywheel monitored grippers of the automatic walking beam
is braked by a variable-frequency drive motor. system in cycle and in the correct position.
The ram ejectors are hydraulically driven single
(7) Weight balancing system ejectors.
For dynamic balancing, the weights of the press The table ejectors are designed as hydraulic posi-
parts moving up and down, including bolster and tion-controlled single ejectors.
dies, are compensated by two pneumatic cylin-
ders. This minimises the bearing clearance of the Lubrication system
components in the power train, thereby positively The main bearings of the machine are continuously
influencing the dynamic loading of the machine ele- lubricated with oil. After leaving the lubrication gap,
ments directly involved. the oil is collected and directed to the recirculating

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 7

5
3

4
9

Intelligent machine design begins with the

selection of the right individual components.

oil unit where it is reconditioned, i.e. cooled and

filtered. The fresh lubricating oil is then pumped
to the lubrication points again. The oil flow to
each lubrication point is hereby monitored elec-
trically. The ram guides are designed as a total-
loss oil lubrication system.
In addition, the bearing temperatures at the main
bearing points of the machine are monitored 10
electrically.

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INDIVIDUAL COMPONENTS

ECCENTRIC SHAFT
n Made of high-alloy quenched and tempered steel
with extra-wide eccentric cams
n High rigidity – low deflection
n Increased fatigue strength thanks to generous
eccentric-to-pinion transition radii

FRAME
n Of split design with tie rods and solid press table
and head section.
n Broad, high windows in all uprights for the inward
transfer of the forging blanks and outward transfer
of the finished part or flash
n Ram guide system of thermally neutral, diagonal
design

PITMAN/RAM
n Double pitman with very wide distance between
supports that corresponds almost to the ram width
to minimise ram tilting
n Minimum wear of the ram guide thanks to
balanced ratio of pitman length to ram stroke

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COMPONENTS

AUTOMATIC ELECTRIC WALKING

BEAM SYSTEM
n Designed for an operating speed of up to 30
strokes per minute
n Comprising four individual housings with drive,
attached to the press frame
n With two replaceable walking beams with their
own drive units which are independent of the
press
n 3 axes of movement: “Transport step”, “Lift/
Lower” and “Open/Close”, each driven by
separate servo motors

HYDRAULIC CLUTCH/BRAKE SYSTEM

n Oil-bath-mounted
n Short response times
n Good heat exchange
n Low noise level
n Almost no wear

ROBOT HANDLING SYSTEMS

n Integration of industrial robots

HOLISTIC CONCEPTS FOR MACHINES

AND PROCESSES THROUGH
n Assurance and optimisation of the operational
sequences on the basis of trial configurations,
e.g. spray stand
n Practical trials

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CONTROL SYSTEM

GENERAL OPERATION
The Siemens S7-1500 control system with failsafe The machine and the installed automation system
CPU and certified press safety software has com- is monitored and operated via a control panel near
plete functional control and monitors the machine the machine for set-up, single stroke and automatic
and its auxiliary units. mode. In conjunction with the integrated visualisa-
tion system, all machine functions can be selected
and executed very easily and efficiently. Depend-
ing on the requirements, the control panel can be
expanded to include an additional operator panel
with enabling push-button for local operation directly
at the machine.

VISUALISATION SYSTEM
The visualisation system employs a 15" touch panel
that also forms an integral part of the control sys-
tem. All necessary machine parameters, measured
values and error messages are displayed to the ma-
chine operator in an intuitive and easily understood
form. Troubleshooting is simplified by an extensive
description, while the integrated initial fault func-
tion focuses the analysis on the crucial aspects. The
complete machine documentation and further tech-
nical documents can be displayed at the machine.

LEVEL 2 / MES
Process data are transmitted via interfaces to
superordinate systems, such as the PC-based SMS
Level2 System. The following MES function mod-
ules have already been implemented:

n MIDIS (order management),

n BDE (process data acquisition),
n FIS (error message management),
n ISS (maintenance management),
n MPT/CM (condition monitoring).

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Also with a view to Industry 4.0, these MES function
modules are subject to ongoing further development
to the special needs of the respective operating
environment and are therefore individually tailored.

TIA PORTAL
The programs of the whole control system consist-
ing of PLC, the visualisation system and possibly the
automation system are integrated into the TIA portal MEASURED VALUE ANALYSER
which thus forms the ideal basis for programming In addition, the machine is equipped with an IBA
with common variable ranges and troubleshooting to measured value and data acquisition system that
support maintenance work. is ideally suited for both simple and individual
troubleshooting and for detecting less frequent fault
CONTROL SYSTEM ARCHITECTURE patterns, e.g. for calibration of the hydraulic clutch.
The architecture of the control system is decen- This system uses signals from existing sensors,
tralised, with the power packs of the table ejector and at the same time records also the signals from
and clutch/brake having dedicated I/O stations in the control program in one measuring cycle so that
the terminal boxes so that they form self-contained a time-critical monitoring of process, sensors and
units. Profinet with Profisafe features is predomi- control system becomes possible.
nantly used as bus system so that e.g. decentralised
emergency stop buttons or safety valves are also REMOTE SERVICE
implemented in the decentralised structure. The comprehensive remote service function has
been made possibly by linking the IBA system with
INTEGRATION the TIA portal. Analysis and diagnosis by record-
Interfacing with existing forging lines, both in con- ing and evaluating the relevant signals through to
junction with a line controller and as direct interfaces program changes are possible here by agreement
to the line components, presents no problems. Here with the machine owner. Provided that the security-
again, Profinet with Profisafe is predominantly used relevant measures are observed, the machine can
so that safety-related signals can also be exchanged. be linked to the SMS group remote service via VPN
(Virtual Private Network) in order to support machine
PRESS FORCE MEASUREMENT maintenance.
A 4-channel press force measuring system which
measures the forces on each side and in each frame
for protection of the machine and for monitoring
of the process by the operator is also lined to the
machine controller via Profinet. The measured value
masks of the visualisation system display both the
individual and total measurements as a bar chart and
measured value, as well as the off-centre loading of
the table in a chart.

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FORGING EXAMPLES

Whether connecting rods, ­journals, transmission

shafts or other closed-die forgings: SMS Meer’s
die-former unites ­traditional forging handicraft with
­automated industrial manufacture – ­precisely, pro-
ductively and cost-­effectively. Here are just a few
­examples from the dieformer’s e ­ xtensive spectrum
of forging ­capabilities.

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THINGS TO KNOW
about the MP

STANDARD VERSION AS OPTIONS

BASIS nL
 ow-wear table coat welding
n Press frame of split design with nA
 djustable ram guides with
tie rods and solid press table and bronze ledges
head section nR
 am dejamming device
n Ram guide with nitrided ledges nT
 op and bottom ejectors for up
n Ram locking device to 5 operations
n Motorised ram adjustment nD
 ie space gates
system nF
 ume extraction hood
n Wet electro-hydraulic clutch/ nH
 ydraulic power pack (for non-
brake system flammable HFC fluid)
nE  lectric flywheel brake nV
 ariable-frequency drive of 4Q
n Hydraulic individual top ejectors design
for 3 operations
n Hydraulic individually controlled EXTENDED OPTIONS SPECIFICATION
table ejectors for 3 operations nD  ie and die design SMS group: Your partner with
n Pneumatic weight balancing nB  olster concepts ideas and profile to match
n Circulating oil lubrication for the n Die and/or bolster quick-clamping
main bearings system SMS group diefomer for closed-
n Protective hoods n Die maintenance and spraying unit die forging ­operations are
n Temperature monitors for the nA  utomation systems such as precisely geared to your require-
main bearings workpiece transfer equipment, ments. You can choose from an
nP  ress force monitor robots and loaders extensive range of performance
n Complete installation nD  ie holder changing systems ­parameters to make all compo-
n Electrical control system with change arm or carriage nents match perfectly, both tech-
n Hydraulic power pack (for min- nT  urnover equipment nically and economically.
eral oil) n Interface incorporated into the
controller of the press periphery

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 © SMS group GmbH · Published on 11.01.2021 · Printed in Germany · KD

SMS group GmbH

Business Unit Forging Plants
Closed-Die Forging

Ohlerkirchweg 66
41069 Mönchengladbach
Germany

Phone: +49 2161 350-1450

P-310E

closeddieforging@[Link]
[Link]

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics
as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation
to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.