The entire world of forging

The entire world

of forging
400E-102009-WSP-2000 Copyright by Schuler

Schuler PRESSen GMBH & CO. KG Schuler SMG GmbH & Co. KG Müller Weingarten AG
Bahnhofstr. 41 | 73033 Göppingen | Germany Louis-Schuler-Str. 1 | 68753 Waghäusel | Germany Schussenstr. 11 | 88250 Weingarten | Germany
Phone + 49 7161 66-307 | Fax + 49 7161 66-729 Phone + 49 7254 988-226 | Fax + 49 7254 988-490 Phone + 49 751 401-2211 | Fax + 49 751 401-2694

forging@schulergroup.com | www.schulergroup.com
63
 Forming the Future

Put it into motion.

Forging with Schuler.

For over 150 years, the name Schuler has been synonymous with innovative technologies, quality and
customer-oriented service in forging technology. Today, you can find us all over the world, wherever
forging systems are used safely and efficiently in production. This claim is backed up by more than 5.000
Schuler employees at our sites in Europe, the USA, Mexico, Brazil, India, China and Russia. Recent
integration of Müller Weingarten AG and the Bêché brand strengthens our position of technological
leadership.

As a leading supplier of cold, warm and hot forging systems, we offer everything from a single source –
from component development and process planning through die making and turnkey installation of
efficient production systems. Schuler forging technology offers you a decisive advantage over your
competitors for productivity and quality.

We hope you enjoy this overview of our extensive range of products and services. When you need high
part quality, maximum production availability and reliable process engineering, we are ready to put it into
motion for you.

We welcome a challenge.
 Contents

FORGING PROCESSES 5
1
1.1 Processes 6
1.2 Temperature ranges 8

PROCESS AND DIE DEVELOPMENT 9

2
2.1 Process development 10
2.2 Die design 11
2.3 Die lubrication and cooling devices 11
2.4 Part feed and transport sequence analysis 12

SYSTEMS FOR COLD FORGING 13

3
3.1 Hydraulic cold extrusion presses 15
3.2 Hydraulic ironing presses 18
3.3 Hydraulic presses for manufacturing CNG gas cylinder tanks 20
3.4 Multi-station mechanical presses with link drive 22

SYSTEMS FOR WARM FORGING 25

4
4.1 Multi-station mechanical presses with eccentric drive 27
4.2 Multi-station mechanical presses with link drive

SYSTEMS FOR HOT FORGING 31

5
5.1 Short-stroke hammers 33
5.2 Counterblow hammers 35
5.3 Screw presses 38
5.4 Crankshaft forging presses 43
5.5 Multi-station mechanical presses with eccentric drive
6 5.6 Hydraulic forging presses 48
5.7 Hydraulic presses for forging ring blanks 50
5.8 Hydraulic presses for forging aluminum wheels 52

GLOBAL SERVICE 55

4
Forging Processes 1

Processes 6

Temperature ranges 8

5
 Forging Processes
Processes
REDUCTION.
Reduction is a forging process in
which the workpiece is forced
through an opening in the die, fully
or in part, involving a reduction in
its cross section. Tapering of solid
bodies results in a reduction in cross
section, whereas hollow bodies, by
contrast, are necked.
Reduction.
6 Forging Processes Processes
EXTRUSION. IRONING.
EXTRUSION is a single or multi-sta- IRONING is carried out by pulling
tion production process for creating the workpiece through an ironing
both hollow and solid bodies. The ring with the help of a punch. The
process is distinguished according wall thickness of the hollow body is
to the direction of material flow: reduced in this process.
forward, backwards or lateral. The
workpiece is forced through an
opening in the die with reduced
cross section giving the workpiece
its shape.
Full forward extrusion. Ironing.
Backward extrusion.
Lateral extrusion.
CLOSED DIE FORGING.
CLOSED DIE FORGING is a forging
process in which dies move towards
each other and covers the work-
piece in whole or in part.
The heated raw material, which is
approximately the shape or size of
the final forged part, is placed in the
bottom die. The shape of the forging
is incorporated in the top or bottom
die as a negative image. Coming
from above, the impact of the top die
on the raw material forms it into the
required forged form.
Closed die forging.
UPSETTING / OPEN DIE FORGING.
UPSETTING and OPEN DIE FORGING
are also forging procedures.
Upsetting is principally used for
preliminary distribution of the
material. In contrast to closed die
forging, the workpiece is not
completely enclosed during this
forging process.
Upsetting.
Open die forging.
PIERCING / TRIMMING.
PIERCING is used for incorporating
holes and openings into a work-
piece, which can have a wide range
of shapes and sizes. TRIMMING
involves removing surplus material
(flash) from the workpiece.
Piercing.
Trimming.
Processes Forging Processes 7
 Forging Processes

Temperature ranges

Increasing degree of deformation

Increasing dimensional accuracy

Hot forging

• Closed die forging

• Forging ring blanks
Warm forging • Upsetting
• Open die forging
• Extrusion • Extrusion
• Upsetting / Setting • Piercing / trimming

Cold forging • Piercing

• Extrusion
• Ironing
• Upsetting / Setting
• Reduction
• Piercing

The different temperature ranges in forging are an important factor when selecting the process
and for successful commercial production.

8 Forging Processes Temperature ranges

Process and die development 2

Process development 10

Die design 11

Die lubrication and cooling device 11

Part feed and transport sequence analysis 12

9
 Process and die development

Process development

We offer the entire process develop-
ment from a single source, including
consulting and training services. To
determine the best economic solu-
tion to produce quality parts, devel-
opment of the forging process
has been decided. Furthermore, the transfer system. These parameters
process plan provides information must be considered simultaneously
about the forging equipment in order to achieve an optimum
required, the die system and the result.
Process development

begins with part design, and must

simultaneously consider material
selection, process technology, pro-
duction stages and die processes. Part feed
and transport
The part design and process plan Die design
sequence
form the basis for calculating the
analysis
economic efficiency in the project
planning phase. This means that the
Selection
decision to use a forging process
of the press
concept

PROCESS DEVELOPMENT. which combinations of forging proc-

The object of developing the part esses should be used: e. g. full for-
design and process plan is to ensure ward extrusion, backward extrusion,
that economical production can be reduction, upsetting, etc.
achieved. It is necessary to consider
the specific application and produc-
PROCESS PLAN FOR TRIPOD HOUSING PRODUCTION
tion situation. For example, if the
production volumes are low then the Warm forging Cold forging
objective is to achieve a process
with only a few forging stations, and
to plan for more complex secondary
machining.
An effective part design and process
plan relies on know-how and practi-
cal experience. During development
of the process plan, the decision
is made which forging process or
 Sequence development 

10 Process and die development Process development

 Process and die development

Die lubrication / cooling device

DIE DESIGN. calibration, punching or trimming 1

In practice, a critical part of die procedures are possible in the same

development is the configuration of operation (using four- or five-station
the punches and dies. Not only the die sets commonly found in opera- 2

punches and dies are accommodat-
ed in the die holder, but also the
other die elements. Modern forging
dies are configured for various sta-
tions. This means additional forging,
tion today). Special dies, such as
closing dies, can also be used. This
significantly reduces production 3
costs related to additional process-
ing after the forging process.
4
5

6
7
1 Ejector pin 7 Die
2 Thrust piece 8 Reinforcement 8
3 Pneumatic spring 9 Counterpunch 9
4 Inner punch 10 Thrust piece
5 Outer punch 11 Ejector pin 10
6 Spraying ring

11

DIE COOLING AND LUBRICATION.

In warm and hot forging presses,
effective cooling and lubrication sys-
tems are required. The shown solu-
tions can provide optimum lubrica-
tion placement. In addition, the dura-
tion of the cooling and lubrication
process can be optimized. This is an
advantage compared to other sys-
tems such as linear manipulators,
swivelling systems or systems that
are mounted on transfer rails.

Die cooling and lubrication systems for warm and hot forging.

Die lubrication / cooling device Process and die development 11

 Process and die development

Part feed and transport

sequence analysis

THE OBJECTIVES OF THE PART FEED AND

TRANSPORT SEQUENCE ANALYSIS

■ Implementing a design with the maximum transport safety

and max. output
■ Collision-free transport of parts from station to station
■ Quick and safe die commissioning
■ Increased stroke rate / output

➔ CASE STUDY
Process and die development

THE CUSTOMER
Automotive components supplier

REQUIREMENT
Complete process development for
manufacturing a tripod housing
with net-shape internal geometry, Tripod housing.

near-net shape quality of outer

dimensions, with required output
of 38 parts / min.

THE SOLUTION
Schuler delivers a turnkey system
with a 5-station die solution includ-
ing die holder. Also, Schuler is
responsible for developing the warm
forging process with subsequent
cold forging and the corresponding
Die set of the multi-station mechanical press with eccentric drive
die cooling and lubrication system. for manufacturing tripod housing.

12 Process and die development Part feed and transport sequence analysis
 Systems for cold forging 3

Hydraulic cold extrusion presses 15

Hydraulic ironing presses 18

Hydraulic presses for manufacturing 20

Compressed Natural Gas (CNG) cylinder tanks

Multi-station mechanical presses with link drive 22

13
 Systems for cold forging

Overview

HYDRAULIC COLD EXTRUSION PRESSES

• Tight parts tolerance
• High-precision workpieces
• Increased output and flexibility
• Large number of forging stations

HYDRAULIC IRONING PRESSES

• No limits on component lengths
• High component quality
• Deep-drawing and ironing operation in one forging procedure

SYSTEMS FOR MANUFACTURING CNG GAS CYLINDER TANKS

• Low material costs for blanks
• Low weight
• Large container diameters are possible
• High surface quality

MULTI-STATION MECHANICAL PRESSES WITH LINK DRIVE

• High output
• Long die life
• Highly complex part shapes
• Optional servo drive

14 Systems for cold forging Overview

 Systems for cold forging

Hydraulic cold
extrusion presses

MH series

HIGH FLEXIBILITY ENSURES
MAXIMUM ECONOMY.
The great flexibility of hydraulic sys-
tems is due to the ability of the user
to program strokes, forces and
speeds to fit the specific application,
which makes cold forging an attrac-
tive solution. Single and multi-station
hydraulic presses have an unlimited
working capacity, offering advan­
tages especially for long shaft-
shaped parts.
Multi-station hydraulic presses
require a very rigid press frame in
conjunction with a tall slide in order
to absorb the high off-center loads
which result from the different force
requirements of the individual sta-
tions.
Schuler’s patented RingValve prefill
valves significantly shorten the cycle
time of the hydraulic press. These
valves provide fast filling of the
hydraulic cylinders during rapid
closing. The pressure in the cylinder
can be released quickly so that the
slide will start the return stroke with-
out delay. Unlike traditional prefill
valves, RingValve prefill valves can
be opened under maximum pressure
at bottom dead center, which signifi-
cantly shortens the press release
portion of the cycle.
Presses with three cylinders allow
Dynamic Force Control (DFC) to be
used. The oil flow is automatically
supplied to one, two or all three
cylinders depending on the force
required. The maximum working
speed is three times faster than con-
ventional presses with the same
drives. As a result, further cycle time
reductions can be achieved, particu-
larly for cold extrusion presses,
where the force requirement does
not rise significantly until the end
of the forging cycle.
Various process sequences can eas-
ily be programmed and saved by the
operator using an on-screen menu
control system. In addition, integrat-
ed and highly flexible part handling
ensures maximum productivity.

THE ADVANTAGES

■ Tight parts tolerances because of rigid press frame and design

■ High-precision workpieces due to precise slide guiding and motorized height
adjustable hard stroke limitations in the bed and below the individual forging
stations
■ Increased output performance due to RingValve technology
■ Part-specific optimization of the press cycle by Dynamic Force Control (DFC)
for high output
■ Low die wear due to low-speed contact (programmable motion curve)
■ Increased flexibility with more forging stations
■ Individually programmable ejectors in the bed and slide

Hydraulic cold extrusion press.

Hydraulic cold extrusion presses Systems for cold forging 15

 SYSTEMS FOR INDIVIDUAL
REQUIREMENTS.
Because of the modular structure
of Schuler’s hydraulic presses, these
cold extrusion presses can be
adapted to the range of parts to be
manufactured, as well as other cus-
tomer requirements (e. g. available
die concepts, spacing between sta-
tions).
Bed and slide surface, die space,
stroke, number of stations and spac-
ing between stations are flexible in
the press design. Ejector concepts,
as well as their forces and strokes,
are defined according to the parts
being manufactured.
Stroke limitations, whether fixed or
adjustable, and die change equip-
ment are integrated as required.
The drive configuration ensures
that required working speeds are
reached, and therefore the desired
output is achieved. The adaptable
press geometry offers design flexibil-
ity for installation of automation with
a tri-axis transfer (for high output) or
robots (for high flexibility).

OVERVIEW OF COLD EXTRUSION PRESS MODELS

Model MH 315 MH 500 MH 630 MH 800 MH 900 MH 1000

Press force [kN] 3.150 5.000 6.300 8.000 9.000 10.000

Max. slide stroke [mm] 250 – 750 250 – 750 500 – 1.000 500 – 1.000 500 – 1.000 500 – 1.250
Number of stations 1 – 3 1 – 3 1 – 4 1 – 4 1 – 4 1 – 5

Model MH 1250 MH 1600 MH 2000 MH 2500 MH 3150 MH 4000

Press force [kN] 12.500 16.000 20.000 25.000 31.500 40.000

Max. slide stroke [mm] 700 – 1.250 700 – 1.250 900 – 1.250 900 – 1.250 900 – 1.250 900 – 1.250
Number of stations 1 – 5 1 – 5 1 – 5 1 – 6 1 – 6 1 – 6
Subject to technical modifications. Different tonnages are available upon request.

➔ APPLICATIONS
Hydraulic cold extrusion presses

Long-shaft components such as:

• Drive shafts
• Axle shafts
• Transmission shafts
• Truck axles

16 Systems for cold forging Hydraulic cold extrusion presses

➔ CASE STUDY
Systems for cold forging – hydraulic cold extrusion presses

THE CUSTOMER THE SOLUTION

Automotive supplier
THE REQUIREMENT
Fully automated press line for
manufacturing shafts weighing up
to 25 kg.
Extremely high flexibility needed –
the customer wishes to extend
product range to non-automotive
parts, such as large specialized
screws.
Schuler supplied one hydraulic five-
station transfer press with Dynamic
Force Control.
– Press capacity: 25.000 kN Hydraulic active grippers with
patented damping system, clamping
– Slide stroke: 1.000 mm force is 10 kN.
• Production rate:
12 parts / min
• Part loading and separation
• Tri-axis Compact Mono Beam
Transfer using hydraulic active
grippers and turnover grippers
• Five die sets
• Die change equipment
Die change arm for quick
changeover.

Loading station. Tri-Axis Compact Mono Beam Transfer.

1 Bin tipper 1
2 Vibration hopper
3 Step feeder
8 7 6 5 4
4 Sorting scale
5 Loading station
6 Tri-Axis Compact Mono Beam Transfer
7 Safety device 2
8 Finished part conveyor
9 Finished part containers 9
10 Press
11 Die change arm
12 Control pendant panel
3

11 10 12

Hydraulic cold extrusion presses Systems for cold forging 17

 Systems for cold forging

Hydraulic ironing presses

MHS series

ECONOMICAL FORGING WITH THE ADVANTAGES

COMBINED DRAWING AND
IRONING IN ONE STROKE. ■ High component quality in terms of accurate dimensions and
Hydraulic presses can form over shape, as well as surface quality

almost unlimited stroke lengths

■ Economical production with combined deep-drawing and ironing
operations in one forging procedure
under force, and therefore are well
■ No limits on component length due to unlimited working strokes of
suited to wall ironing. In addition to
hydraulic press systems
traditional vertical forging systems, ■ High output performance, particularly with horizontal press
Schuler also offers horizontal press- systems using two die chambers
es. With ingenious integration of two
die chambers in this design, the
return stroke of the slide can also be
used for forging, thereby increasing
productivity.

Very long components can be produced on Blanks and cups are processed on the same machine without any
hydraulic ironing presses. return stroke.

OVERVIEW OF HYDRAULIC IRONING PRESSES IN HORIZONTAL DESIGN

Model MHS 63 / 63 MHS 80 / 80 MHS 100 / 100 MHS 125 / 125 MHS 160 / 160 MHS 200 / 200 MHS 250 / 250 MHS 315 / 315

Press force [kN] 2 × 630 2 × 800 2 × 1.000 2 × 1.250 2 × 1.600 2 × 2.000 2 × 2.500 2 × 3.150

Number of die
2 2 2 2 2 2 2 2
chambers

Model MHS 400 / 400 MHS 500 / 500 MHS 630 / 630 MHS 800 / 800 MHS 1000 / 1000 MHS 1250 / 1250 MHS 1600 / 1600

Press force [kN] 2 × 4.000 2 × 5.000 2 × 6.300 2 × 8.000 2 × 10.000 2 × 12.500 2 × 16.000

Number of die
2 2 2 2 2 2 2
chambers

Subject to technical modifications. Different tonnages are available upon request.

18 Systems for cold forging Hydraulic ironing presses

 MH series

WHETHER SHORT OR LONG –

NET SHAPE IS THE GOAL.
As a rule, one ironing operation is
sufficient for calibrating precise
components. Long, thin walled parts
are generated in one stroke by rela-
tively large reductions in the wall
thickness on presses with long
stroke length and several ironing
rings arranged consecutively. The
blanks are pulled through the die
with the punch. In one cycle, the
wall thickness is reduced precisely
to the required dimension, the ulti-
mate shape is created and the sur-
face is smoothed.
Extreme slide strokes require Manipulators transferring the blank
extreme press dimensions. from the parts conveyor into the die.

OVERVIEW OF VERTICAL HYDRAULIC IRONING PRESSES

Model MH 250 MH 315 MH 400 MH 500 MH 630 MH 800 MH 1000 MH 1250 MH 1600

Press force [kN] 2.500 3.150 4.000 5.000 6.300 8.000 10.000 12.500 16.000

Number of die
1 1 1 1 1 1 1 1 1
chambers

Subject to technical modifications. Different tonnages are available upon request.

➔ APPLICATIONS
Hydraulic ironing presses

Long, thin walled parts such as

• CO2 cartridges
• Shock absorbers
• Hollow shafts

Hydraulic ironing presses Systems for cold forging 19

 Systems for cold forging

Hydraulic presses for manufacturing

CNG gas cylinder tanks

MH series

COMPRESSED NATURAL GAS FOR
A CLEANER FUTURE.
Today, more and more vehicles are
driven with alternative fuels. The
travel distance of gas-fuelled vehi-
cles depends significantly on the
vehicle weight and the fill volume of
the fuel tank. To deal adequately
with both of these factors, it is nec-
essary for the compressed natural
gas (CNG) containers to withstand
considerable internal pressure and
also be lightweight in design.
Beginning with the blank, CNG con-
tainers are manufactured on Schuler
machines in several drawing/ironing
operations. A blank holder is inte-
grated depending on the forging sta-
tion.
THE ADVANTAGES
■ Lower material cost of blanks as compared to precision tubes
■ Lower weight than traditionally forged containers
■ Larger container diameters are possible compared to
traditional forging
■ High surface quality

Die space. Line with three hydraulic presses for manufacturing CNG gas cylinder tanks.
Press forces: 19.000, 12.000 and 8.000 kN.

20 Systems for cold forging Hydraulic presses for manufacturing CNG gas cylinder tanks
 CNG CONTAINERS: FROM
INEXPENSIVE BLANKS.
Manufacturing CNG gas cylinder
tanks from blanks offers many
advantages.
Blanks are easier and less expensive
to manufacture than seamless preci-
sion tubes. In addition, they have
thinner bottoms compared to con-
tainers forged from a solid block.
High surface quality is guaranteed
by the integrated ironing process.
Fully automated production process-
es and fast changeovers maximize
productivity for the system.

Part transfer between presses with robots.

➔ APPLICATIONS
Hydraulic presses for manufacturing CNG gas cylinder tanks

• CNG gas cylinder tanks

Hydraulic presses for manufacturing CNG gas cylinder tanks Systems for cold forging 21
 Systems for cold forging
Multi-station mechanical presses
with link drive
MML series
EFFICIENCY, STEP BY STEP.
Multi-station mechanical presses
with link drive are suitable not only
for high-volume production of small
components but also for producing a
variety of shafts, due to the large
range of slide strokes. The latest
control systems make it possible to
integrate the presses easily into fully
automated production systems.
Multi-station mechanical press for cold forging transmission shafts.
Press force: 16.000 kN, slide stroke: 800 mm.
22 Systems for cold forging Multi-station mechanical presses with link drive
The variety of features and available THE ADVANTAGES
functions such as bed and slide
ejectors, blank feeding, transfer and ■ High output rate
die changes means that the systems ■ Reduced forging speed
■ Longer die life
can be used for specific applications
■ Wide range of applications
or flexibly optimized for a wide range
of applications. The various designs
for kinematic motion of the slide that
can be selected enable these press-
es to be configured for warm forging
as well.
Stroke
Conventional
eccentric drive
Motion sequence
with link drive
The link drive system permits high output rates and Time
production with reduced die wear.
 OVERVIEW OF Multi-station mechanical presses with link drive
Model MML 315 MML 400 MML 630 MML 800 MML 1000

Press force [kN] 3.150 4.000 6.300 8.000 10.000

250 250 315 315 400

Ram stroke [mm]
500 500 500 500 630

Stroke rate 30 – 60 30 – 60 25 – 50 25 – 55 25 – 50
[strokes / min] 22 – 45 22 – 45 25 – 50 22 – 45 18 – 38

Bed surface
1.000 × 600 1.000 × 600 1.250 × 710 1.250 × 710 1.500 × 1.000
[lr × fb mm]

Model MML 1200 MML 1600 MML 2000 MML 2500 MML 3150

Press force [kN] 12.000 16.000 20.000 25.000 31.500

400 630 630 630 630

Ram stroke [mm]
630 800 800 800 800

Stroke rate 25 – 50 18 – 40 18 – 40 18 – 36 18 – 36
[strokes / min] 18 – 38 16 – 36 16 – 36 16 – 32 16 – 32

Bed surface
1.500 × 1.000 1.800 × 1.000 1.800 × 1.000 2.200 × 1.000 2.200 × 1.000
[lr × fb mm]

Subject to technical modifications.

Link drive system for multi-station

mechanical presses.

➔ APPLICATIONS
Multi-station mechanical presses with link drive

Parts for:
• Engines / transmissions
• Drive components
• Suspension components
• Fasteners
• Roller bearing elements

Multi-station mechanical presses with link drive Systems for cold forging 23
 MSL series

COMBINATION WITH SERVO THE ADVANTAGES WITH OPTIONAL SERVO DRIVE

DRIVE.
Combining the link drive system with
servo drive technology makes it
possible to improve upon the advan-
tages of the link drive concept. This
results in highly flexible production
systems with increased output rates.
■ Increased output rates
■ Individually programmable ram speeds and motion
sequences
■ Ability to optimize the forging process
■ High component quality and long die life
■ Ability to adapt slide movement to the transport sequence
■ Sensitive tryout operation possible
■ Optimized energy consumption

➔ CASE STUDY
Systems for cold forging – multi-station mechanical presses with link drive

THE CUSTOMER • Production rate: 50 parts / min

Automotive supplier
THE REQUIREMENT
Supply a turnkey solution for eco-
nomical series production of steer-
ing system components in the auto-
motive industry.
• 3-axis servo transfer system
• Automatic feed system with
bin tipper
• Die lubrication system
• Die change equipment

SYSTEM SOLUTION
Schuler supplied a multi-station
mechanical press with link drive:
– Press force: 8.000 kN
– Ram stroke: 450 mm

Schuler supplied a multi-station, mechanical press with link drive,

press force 8.000 kN.

24 Systems for cold forging Multi-station mechanical presses with link drive
Systems for warm forging 4

Multi-station mechanical presses 27

with eccentric drive

Multi-station mechanical presses

with link drive

Systems for warm forging 25

 Systems for warm forging

Overview

MULTI-STATION MECHANICAL PRESSES WITH ECCENTRIC DRIVE

• Wide press force range • Large die space
• Very good output • Long die lifes
• Long stroke lengths • Short contact time

MULTI-STATION MECHANICAL PRESSES WITH LINK DRIVE

• High output
• Large die space
• High component quality

➔ Information about multi-station mechanical presses with link drive

can be found starting on page 22

26 Systems for warm forging Overview

 Systems for warm forging

Multi-station mechanical presses

with eccentric drive

MME series

SHORT CONTACT TIMES. to achieve long stroke lengths THE ADVANTAGES

Multi-station mechanical presses of 1.000 mm or even more. The gen-
with eccentric drive are well suited erously sized die space permits the ■ Long stroke length
for warm forging due to the sinusoi- use of heavily reinforced dies. In ■ High output rates

dal motion sequence, as there is a

short contact time and sufficient
non-contact time available for die
cooling. This series of presses can
be configured with 1 or 2-point slide
attachment, and offers a wide range
of rated press forces, with the ability
■ Minimum contact times
order to make a fully automated pro-
■ Extended non-contact times for
duction line, the flexible controls can
die cooling
incorporate a wide range of periph-
■ Long die life
eral devices. ■ Large die space
■ Tight component tolerances
and high component quality
■ Optional servo drive

OVERVIEW OF MULTI-STATION MECHANICAL PRESS MODELS WITH ECCENTRIC DRIVE

Model MME 315 MME 400 MME 630 MME 800 MME 1000

Press force [kN] 3.150 4.000 6.300 8.000 10.000

250 250 315 315 400

Ram stroke [mm]
500 500 500 500 630

Stroke rate 30 – 60 30 – 60 25 – 50 25 – 55 25 – 50
[strokes / min] 22 – 45 22 – 45 25 – 50 22 – 45 18 – 38

Bed surface
1.000 × 600 1.000 × 600 1.250 × 710 1.250 × 710 1.500 × 1.000
[lr × fb mm]

Model MME 1200 MME 1600 MME 2000 MME 2500 MME 3150

Press force [kN] 12.000 16.000 20.000 25.000 31.500

400 630 630 630 630

Ram stroke [mm]
630 800 800 800 800

Stroke rate 25 – 50 18 – 40 18 – 40 18 – 36 18 – 36
[strokes / min] 18 – 38 16 – 36 16 – 36 16 – 32 16 – 32

Bed surface 2.300 × 1.000 2.300 × 1.000 2.300 × 1.000 2.300 × 1.000
1.500 × 1.000
[lr × fb mm] (1.750 × 1.000) (1.750 × 1.000) (1.750 × 1.000) (1.750 × 1.000)

Subject to technical modifications.

Multi-station mechanical presses with eccentric drive Systems for warm forging 27
 The classic eccentric drive in its
compact design offers a range of
advantages, particularly suitable for
use in warm forging. The drive kine-
matics, which can optionally be con-
figured with a servo drive, combined
with the high-performance bed and
ram ejector systems, offer the best
conditions for reliable workpiece
handling and high output.
Combination with multiple feeder
and transfer devices is also possible.
These advantages can also be used
successfully in applications involving
NC-transfer and die space area.
cold forging and precision forging.

Stroke

Eccentric sequence

Eccentric drive in compact design. The eccentric drive provides economical Time
high-volume production.

28 Systems for warm forging Multi-station mechanical presses with eccentric drive
 MSE series

COMBINATION WITH SERVO THE ADVANTAGES WITH OPTIONAL SERVO DRIVE

DRIVE.
Combining the eccentric drive sys-
tem with servo drives makes it possi-
ble to extend the advantages of this
drive concept. The result is a highly
flexible production system with
increased output rates.
■ Increased output rates
■ Individually programmable ram speeds and motion
sequences
■ Ability to adapt motion sequence to the forging process
■ High component quality and long die life
■ Ability to adapt slide movement to the transport sequence
■ Sensitive tryout operation possible
■ Optimized energy consumption

Stroke

Conventional
eccentric drive

Various slide kinematics are possible with Time

optional servo drive.

➔ APPLICATIONS
Multi-station mechanical presses with eccentric drive

Parts for:
• Engines / transmissions
• Drive components
• Suspension components
• Fasteners
• Roller bearing elements

Multi-station mechanical presses with eccentric drive Systems for warm forging 29
➔ CASE STUDY
Systems for warm forging – multi-station mechanical presses with eccentric drive

THE CUSTOMER • Output rate: 38 parts / min

Automotive supplier • Induction heating with parts feed
and temperature monitoring, with
THE REQUIREMENT a system for gating-out parts
Deliver a fully automated line for • 3-axis servo transfer system
warm forging production of driveline • Cooling section
components • Extensive die, cooling and
lubrication accessories
SYSTEM SOLUTION
Schuler delivered a multi-station
mechanical press with eccentric
drive:
– Press force: 20.000 kN
– Ram stroke: 800 mm
15 14

8 6 1 5

19 18

1 Bin tipper
2 Vibration hopper
3 Step feeder
10 11 9 7
4 Scale with sorting device
5 Lateral transport conveyor
6 Pre-graphitizing station
7 Graphite tank
8 Induction heating 16 14 17 12 13
9 Die lubrication tank
10 Conveyor for colder part removal 1
11 Container for colder parts
12 Operating panel
13 Protective device on the infeed side
14 Transfer system
15 Press 2 4
16 Protective device on the exit end 16 15 14 13
17 Die change arm 8 3
18 Cooling section
19 Finished parts container
5

10 11 7

9
6
19 18 17

30 Systems for warm forging Multi-station mechanical presses with eccentric drive
 5
Systems for hot forging

Short-stroke hammers 33

Counterblow hammers 35

Screw presses 38

Crank forging presses 43

Multi-station mechanical presses with eccentric drive

Hydraulic forging presses 48

Hydraulic presses for forging ring blanks 50

Hydraulic presses for forging aluminum wheels 52

Systems for hot forging 31

 Systems for hot forging

Overview

SHORT-STROKE HAMMERS
• Very high stroke rates
• Minimum pressure contact times
• Low operating costs

COUNTERBLOW HAMMERS
• Extremely high impact energy and forging power (tonnage)
• High reliability and availability
• High stability of the overall structure

SCREW PRESSES
• Wide range of parts
• High repeat accuracy
• High reliability

CRANK FORGING PRESSES

• High production speed
• Fully automated parts handling
• High production accuracy

MULTI-STATION MECHANICAL PRESSES WITH ECCENTRIC DRIVE

• Long stroke lengths
• Large die space ➔ More information about multi-station mechanical presses
• Precision forging with eccentric drive can be found on page 27

HYDRAULIC FORGING PRESSES

• More accurate pre-forging with high press forces, therefore reduced rolling work
• Weight savings due to greater accuracy
• High output

HYDRAULIC PRESSES FOR FORGING RING BLANKS

• High forces for extremely large parts
• High flexibility / high output
• Proven press concepts

HYDRAULIC PRESSES FOR FORGING ALUMINUM WHEELS

• Highest possible press forces in compact space
• Proven press concepts
• High precision and quality of forged wheels

32 Systems for hot forging Overview

 Systems for hot forging

Short-stroke hammers

KGH series

MAXIMUM EFFICIENCY EVEN IN THE ADVANTAGES

SMALL-TO-MEDIUM BATCH SIZES.
Short-stroke hammers are used ■ High stroke rate
for many kinds of applications, ■ Minimum contact times

and are particularly suitable for

■ Low operating costs
■ Simple operation
small-to-medium sized parts. The
■ Guides with large surface area
sturdy, monoblock U-frame design,
■ Universally applicable
in conjunction with precise guides
with a large surface area, provides
high forging accuracy. The hydrau-
ADDITIONAL EQUIPMENT
lic down stroke drive permits high
stroke rates combined with minimum ■ Automation
contact times. The modern control ■ Anvil bed heating
system permits precise adjustment ■ Anti-vibration installation
of the impact energy and stroke rate. ■ Acoustic insulation
■ Customer-specific custom solutions

Short-stroke hammers with Fully automatic production on a short-stroke hammer

solid U-frame. with robot automation.

Short-stroke hammers Systems for hot forging 33

 OVERVIEW OF SHORT-STROKE HAMMER MODELS
Model KGH 1,6 KGH 2 KGH 2,5 KGH 3,15 KGH 4 KGH 5 KGH 6,3 KGH 8 KGH 10 KGH 12,5 KGH 16

Working capacity [kJ] 16 20 25 31,5 40 50 63 80 100 125 160

Impact frequency max.

122 120 113 100 98 98 95 92 83 75 70
[per min]
Slide stroke max. [mm] 635 665 685 755 790 775 805 835 885 1.060 960

Slide depth [mm] 470 510 550 595 640 695 750 830 890 1.020 1.045

Clearance between
520 570 608 664 717 766 831 890 960 1.060 1.060
guides [mm]
Total die height max.
320 345 360 420 455 435 465 495 540 580 620
[mm]

Total weight [t] 24 30 36 46 60 75 96 121 143 195 235

Subject to technical modifications.

1
2
3
4
5
6
1 Drive head
2 Piston rod
3 Slide
4 Upper die
5 U-frame
6 Lower die

Drive head of a KGH 2,5.

➔ APPLICATIONS
Short-stroke hammers

• Chassis components
• Flanges
• Connecting rods
• Turbine blades
• Hand tools

34 Systems for hot forging Short-stroke hammers

 Systems for hot forging

Counterblow hammers

FOR LARGE FORGED PARTS. THE ADVANTAGES ADDITIONAL EQUIPMENT

BÊCHÉ counterblow hammers are
predominantly used for manufactur- ■ Extremely high impact energy ■ Die change systems

ing large and ultra-large forgings. and tonnage ■ Tup heating systems
■ High reliability and availability ■ Ejector systems
The high impact energy and tonnage
■ High stability of the overall ■ Spraying systems
of the hammer dies, moving in oppo-
structure
site directions, permits precision
■ High precision with large
forming of large forgings. forgings
■ Hydraulic tup coupling
■ Long stroke for accessibility

Hydraulic counterblow hammers HG series

Counterblow hammers with hydrau- 1 Drive head

2 Piston rod
lic drives are particularly well suited 3 Upper tup
4 Upper die
to the medium tonnage range. This 5 Upright
means there is no need for a compli- 6 Tup support
7 Lower die 1
cated compressed air installation. 8 Lower tup
9 Hydraulic tup coupling 2
10 Buffer 3

5
OVERVIEW OF HYDRAULIC COUNTERBLOW HAMMER MODELS
6
Model HG 16 HG 20 HG 25 HG 31,5 HG 40
7
160 200 250 315 400 8
Working capacity [kJ]
Impact frequency max.
50 50 50 45 45
[per min]
Slide stroke max. [mm] 630 710 710 760 760
9
Slide depth [mm] 1.450 1.600 1.750 1.800 2.150 10
Clearance between guides
1.100 1.200 1.300 1.350 1.500
[mm]
Total die height max. [mm] 315 355 355 400 450

Total weight [t] 133 161 203 255 322

Subject to technical modifications.

Counterblow hammers Systems for hot forging 35

 1

3
DG series
4
5

Pneumatic counterblow 6

hammers
This series employs the proven 7 DG 140
pneumatic drive concept. It allows
very large forging energy levels to 1 Top part of machine
2 Upper tup
be achieved. The sturdy design of 3 Upper die 8
the uprights, together with a solid 4 Upright
9
5 Tup support
guide system, ensures high precision 6 Lower die
7 Lower tup
during forging. 8 Hydraulic slide coupling
9 Buffer

OVERVIEW OF PNEUMATIC COUNTERBLOW HAMMER MODELS

Model DG 16 DG 20 DG 25 DG 31,5 DG 40 DG 50 DG 63 DG 80 DG 100 DG 125 DG 140

Working capacity [kJ] 160 200 250 315 400 500 630 800 1.000 1.250 1.400

Impact frequency max.

50 45 45 40 40 36 36 32 28 25 25
[per min]
Slide stroke max. [mm] 745 840 840 910 960 970 1.020 1.035 1.100 1.150 1.225

Slide depth [mm] 1.450 1.600 1.750 1.800 2.150 2.400 2.700 3.000 3.400 3.600 3.700

Clearance between guides

1.100 1.200 1.300 1.350 1.500 1.500 1.600 1.600 1.700 1.900 2.000
[mm]
Total die height max. [mm] 315 355 355 400 450 450 450 500 550 550 600

Total weight [t] 120 145 180 210 185 355 433 650 850 1.050 1.200

Subject to technical modifications.

➔ APPLICATIONS
Counterblow hammers

• Crankshafts
• Turbine blades
• Driveline and chassis components for
cars and trucks
• Flanges and disks

36 Systems for hot forging Counterblow hammers

➔ CASE STUDY
Systems for hot forging – counterblow hammers

THE CUSTOMER
Components industry

THE REQUIREMENTS
Economical production of large
crankshafts with a component length
up to four meters and weighing up to
3.000 kg each.

THE SOLUTION
Müller Weingarten designed and
manufactured a semi-automated
forging line, based upon the DG 80 h
counterblow hammer. The entire
forging line is equipped with an
advanced control concept for opti-
mizing the process parameters and
material flow, based on an innova- Production of crankshafts on a counterblow hammer
tive logic function. with a rated capacity of 800 kJ.

1 Manipulator
2 Storage area
3 Furnace
4 Descaling
5 Drop machine
6 Counterblow hammer
7 Trimming and calibrating press

2 3 1 4 5 3 2 4 1 6 7

Semi-automated forging line with counterblow hammer and trimming /calibrating press.

Counterblow hammers Systems for hot forging 37

 Systems for hot forging

Screw presses

SCREW PRESSES ARE VIRTUOSOS.
Thanks to almost 120 years of expe-
rience in building screw presses,
with continuous developments, there
is practically no drop forging that
cannot be manufactured using a
screw press. As far back as 1936,
the conventional friction drive was
superseded by the friction roller
drive and, subsequently, direct drive.
From 1963 onward, once reliable
three-phase synchronous motors
with rapid permitted switching fre-
quencies were available; the door
was open to a new and ideal drive
system for screw presses.
In this direct drive, the torque from
the drive motor is transmitted to the
screw without intermediate drive
components, wear parts or energy
losses. This drive concept repre-
sents the optimum design solution
for a screw press drive – in terms of
robustness, reliability, maintenance
and efficiency.
THE ADVANTAGES

■ Wide range of parts

■ High repeat accuracy

1 Cooling motor
■ High reliability
2 Main motor stator with 1 ■ High flexibility
motor housing
3 Rotor shrunk onto
■ Maximum efficiency
flywheel 2 ■ Frequency Drive
4 Screw
5 Crown
6 Thrust bearing 3
7 Tie bar ADDITIONAL EQUIPMENT
4
5
■ Ejector in the bed and slide
6
■ Die change systems
7
■ Customer-specific solutions

Drive system of a screw press.

➔ APPLICATIONS
Screw presses

• Forgings for the automotive industry and commercial

vehicles such as crankshafts, axles, connecting rods
or transverse links
• Fittings
• Flanges
• Hand tools, cutlery
• Surgical instruments as well as turbine components

38 Systems for hot forging Screw presses

 PA series

PA SERIES. non-ferrous metals and requiring

The body of the press in the PA high precision can be forged effi-
series is a monoblock design. In par- ciently on type PA screw presses.
ticular, small components made from

OVERVIEW OF SERIES PA SCREW PRESS MODELS

Model PA 125 PA 140 PA 160 PA 180 PA 200 PA 225

Screw diameter [mm] 125 140 160 180 200 225

Continuously permitted press [kN] 2.500 3.200 4.000 5.000 6.400 8.000

Die-to-die blow force [kN]. 3.200 4.000 5.000 6.300 8.000 10.000

Gross working capacity [kJ] 4,5 6,5 10 14 19 27

Available stroke rate (thermal) [min ] -1

32 30 28 26 24 21

Distance bed – slide max. [mm] 620 670 730 790 850 940

Bed surface [mm] 460 × 500 500 × 550 540 × 570 580 × 610 620 × 650 680 × 710

Total weight [t] 4 6 8 10 14 20

Subject to technical modifications.

1 Drive
2 Frame
3 Ram
4 Upper die
5 Lower die

A type PA spindle press can also be used for producing

components from non-ferrous metals.

Screw presses Systems for hot forging 39

 PSM / PSH series

PSM / PSH SERIES. 1
The medium PSM / PSH series are
produced as a two-piece casting
held together by four tie rods. In the 2
PSM series, the tie rods absorb sur-
plus energy once a defined forging 3

force has been reached, protecting 4

the press against overload. In addi-
5
tion, the PSH series features a
hydraulic overload protection sys- 6
tem. This system allows the press to 7

be equipped with a higher working

energy, which is necessary when
large forgings are involved. The 8
series has a frequency drive. This
1 Drive 5 Frame
not only allows precise control, but 2 Crown 6 Upper die
3 Screw 7 Die change arm (option)
also delivers improved efficiency
4 Ram 8 Lower die
and better repetitive accuracy.

OVERVIEW OF SERIES PSM SCREW PRESS MODELS

Model PSM 265 PSM 300 PSM 325  PSM 360  PSM 400 PSM 450 PSM 500 PSM 560 PSM 630 

Screw diameter [mm] 265 300 325 360 400 450 500 560 630

Continuously permitted press [kN] 11.000 14.000 16.000 21.000 26.000 32.000 40.000 50.000 64.000

Die-to-die blow force [kN]. 14.000 18.000 20.000 26.000 32.000 40.000 50.000 63.000 80.000

Gross working capacity PSM [kJ] 65  100  120 160 210 315 400 500  700

Gross working capacity PSH [kJ] 90 140 170 225 300 420 560 700 1000

Distance bed – slide max. [mm] 780 860 920 1.000 1.080 1.200 1.300 1.450 1.460

Bed surface [mm] 750 × 860 820 × 870 860 × 920 930 × 1.000 1.000 × 1.080 1.100 × 1.180 1.200 × 1.280 1.320 × 1.400 1.600 × 1.990

Total weight [t] 40 55 67 86 112 150 196 260 350

Subject to technical modifications.

40 Systems for hot forging Screw presses

 PZS series
1

PZS SERIES.
The frame of PZS presses in this
series is a four-piece casting held 2

together by four tie rods. The drive

comes from several motors linked
via a bull gear to the external diame-
ter of the flywheel. 1 Flywheel
The press force is limited by a slip- 2 Motor
3 3 Crown
ping clutch in the flywheel. 4 Ram
5 Upper die
6 Upright
7 Lower die
8 Bed

Machining a screw at the Weingarten facility.

OVERVIEW OF SERIES PZS SCREW PRESS MODELS

Model PZS 710 PZS 800 PZS 900 PZS 1000 PZS 1120 PZS 1200 PZS 1325

Screw diameter [mm] 710 800 900 1.000 1.120 1.200 1.325

Continuously permitted press [kN] 80.000 100.000 128.000 160.000 200.000 230.000 280.000

Die-to-die blow force [kN]. 100.000 126.000 160.000 200.000 250.000 290.000 360.000

Gross working capacity [kJ] 1.150 / 2.200 1.650 / 3.000 2.250 / 4.000 3.150 / 6.000 4.000 / 6.800 5.000 / 8.500 7.000 / 10.000

Available stroke rate (thermal) [min-1] 10 9 9 8 8 7 4

Distance bed – slide max. [mm] 1.200 1.700 1.800 2.000 2.000 2.200 2.300

Bed surface [mm] 1.600 × 2.000 2.050 × 2.000 2.100 × 2.200 2.400 × 3.000 2.400 × 3.000 2.600 × 3.000 3.100 × 3.700

Total weight [t] 450 700 980 1.150 1.400 1.800 2.400

Subject to technical modifications.

Screw presses Systems for hot forging 41

➔ CASE STUDY
Systems for hot forging – screw presses

THE CUSTOMER
Manufacturer of heavy duty truck
engine components.

THE REQUIREMENTS
System for automated production of
truck crankshafts and truck front
axles.

THE SOLUTION
Müller Weingarten supplied a com-
plete, fully automated forging line. A
PZS 900f screw press is used as the
main forging machine. All necessary
process steps such as rolling, pre-
forming forging, finish forging, trim-
ming, twisting and calibrating are
accomplished in the line. Screw press of the PZS-series in operation.

1 2 3 4

1 Rotary hearth furnace

2 Descaling
3 Reducer roll 8
4 Screw press PZS 900f
5 Robot / manipulator
6 Trimming and calibrating press
7 Twister
8 Calibrating press
9 Cooling section
9

42 Systems for hot forging Screw presses

 Systems for hot forging

Crank forging presses

PK series

SpeedForge crank forging presses

SpeedForge. THE ADVANTAGES
Mechanical high-performance crank
forging presses are particularly well ■ High production speed
suited to fully automated production ■ Fully automated parts handling

of high volume forgings. The frame

■ High production accuracy
■ High rigidity
and drive system are designed for
■ Efficient series production
high load and production precision.
An extensive range of equipment
including material feed, transfer sys- ADDITIONAL EQUIPMENT
tem and finished part removal,
spraying system and die change ■ Ejector in the bed and slide
■ Servo transfer
makes it possible to adapt the press-
■ Feeder
es to various production jobs with
■ Die change system
ease. These presses can be effi- ■ Spraying system
ciently used both for steel and non-
ferrous materials.

5
6

1 Drive 7
2 Crown 9 8
3 Crankshaft
4 Upright
5 Ram
6 Ram ejector 10
7 Die holder 11
8 Transfer
9 Die
10 Bed ejector
11 Bed

Crank forging presses Systems for hot forging 43

 Crank forging presses with DualDrive
DUALDRIVE OPENS NEW
HORIZONS.
The newly developed DualDrive
concept for crank forging presses
With this drive concept, called THE ADVANTAGES
DualDrive, it is possible to vary the
ram speeds between 6 and 12 ■ Reduced contact time
strokes / min. in the TDC area and ■ Reduced die wear

makes it possible to move through

the top dead center position at a
very low ram speed, and move
through the bottom dead center
position at a very high ram speed.
The forging press is equipped with
two drives for this kind of high-per-
formance.
1. A conventional main drive with fly-
wheel, clutch / brake combination
with freewheel and planetary gear
unit.
■ More time for die cooling and part
between 60 and 120 strokes / min. in
transport
the BDC area. As a result, the die
contact times can be cut to a mini-
mum, thereby extending the die life.
Also, the time available for die cool-
ing and for parts transport is longer.
This means the productivity of the
press can be increased significantly
by full capacity utilization. Output
rates of up to 40 parts / min are pos-
sible, depending on the part size.
1 DualDrive
2 Crank shaft
3 Flywheel drive
4 Flywheel

2. A controlled auxiliary drive for the

sections in which no forging takes 1 2 3 4
place.

Stroke [mm]
300

250
DualDrive
200

150

100
Conventional
eccentric drive
50

Contact time
0
0 0,5 1,0 Time [s]
Reduced pressure contact time with DualDrive.

44 Systems for hot forging Crank forging presses

 OVERVIEW OF CRANK FORGING PRESS MODELS
Model PK 1250 PK 2000 PK 3150 PK 4000 PK 5000 PK 6300

Nominal force [kN] 12.500 20.000 31.500 40.000 50.000 63.000

Stroke rate continuous [1 / min]. 70 65 60 60 50 40

Working capacity single [kJ] 180 320 550 750 1.000 1.300

Ram stroke [mm] 300 300 400 400 450 450

Ram adjustment [mm] 20 20 25 25 25 25

Shut height [mm] 850 1.100 1.500 1.500 1.700 1.700

Bed depth [mm] 1.050 1.320 1.390 1.450 1.500 1.600

Bed width [mm] 1.280 1.480 2.170 2.200 2.250 2.300

Subject to technical modifications.

Main drive of crank forging press PK 3150. Planetary gearbox between flywheel and crank shaft.

➔ APPLICATIONS
Crank forging presses

• Chassis components
• Flanges
• Drive components
• Bearing races
• Gear blanks

Crank forging presses Systems for hot forging 45

➔ CASE STUDY
Systems for hot forging – crank forging presses

THE CUSTOMER DualDrive, hydraulic ejectors and

Automotive components industry
THE REQUIREMENTS
Fully automated production system
for flanges with high output.
THE SOLUTION
Müller Weingarten supplied a com-
plete production line comprised of
part feed, induction heating system,
PK 3150 crank forging press with
complete automation system as well
as part removal with controlled cool-
ing. The package also included die
holders, dies and a die change sys-
tem. The forging line manufactures
various flanges with a productive
output of 30 parts / min, in a flash-free
production process involving five
forging stations.

PK 3150 with Dual Drive.

Multi-station die of a crank forging press of the PK-series.

46 Systems for hot forging Crank forging presses

 PRESS CONTROL SYSTEM
MW FORGE CONTROL SYSTEM
(FCS)
The MW-FCS control system repre-
sents the latest development in
control systems for screw presses
and forging hammers. It has been
developed especially for forging
machines, and combines the latest
features for high flexibility and high
accuracy in controlling machine
parameters. Depending on the
machine and application, the stand-
ard functions include a wide range
of stroke control options or impact
program specifications, energy and
part thickness measurement, control
loops for energy and TDC position,
as well as documentation functions
for die and production data.
Simple operation with graphical user interface.
THE ADVANTAGES
■ Ease of operation because of uniform graphical user interface with
touch screen
■ Access to machine documentation, circuit diagrams and fluid diagrams
■ Remote maintenance and diagnosis
■ Interfaces for external data storage as well as print function, including
integration in a customer’s network
■ Control loops to ensure that process parameters are observed, especially
for screw presses
■ Monitoring functions for parameters affecting quality, such as impact
energy, part thickness, impact force, part temperature
■ Required impact energy can be applied precisely
■ Visualization in almost every customer’s language
ADDITIONAL EQUIPMENT
■ MDA-Machine data acquisition
■ Barcode scanner
■ Pyrometer for part temperature
■ Central control for forging cells with central data storage and data
management
■ Interlinking interfaces and, if required, control functions to customer’s
forging peripherals
■ Energy feedback into the power system when operating screw press with
frequency inverter
■ Heating with control loops for top and bottom
■ Customer-specific special functions
Uniform touch screen user interface.
Crank forging presses Systems for hot forging 47
 Systems for hot forging

Hydraulic forging presses

MH series

FORGING RAILWAY WHEELS.

Railway wheels are manufactured in
three forging stages before they are
processed further with machining
(metal cutting). First, the heated
billet is pressed into a disk-shaped
pre-form on a pre-form press. Next,
this blank is rolled into the shape of
a wheel on a rolling machine. Last,
the rolled wheel is shaped in a cali-
brating press and a hole is pierced in
the hub. Hydraulic presses with
Hydraulic press for forging railway wheels.
press forces up to 100.000 kN are
used for pre-forging the wheels. As
a rule, press forces from 20.000 to
50.000 kN are required for shaping THE ADVANTAGES
and piercing.
■ High press forces achieve
more accurate pre-forging,
reducing rolling work
■ Weight saving due to greater
accuracy
■ High output

➔ APPLICATIONS
Hydraulic forging presses

• Railway wheels for cars

• Railway wheels for engines

48 Systems for hot forging Hydraulic forging presses

 EXAMPLES OF HYDRAULIC
FORGING PRESSES.
The working sequences before and
after the actual forging are frequent-
ly performed on hydraulic presses.
On hydraulic pre-form presses, pre-
forms are generated so that there
will be a mass distribution appropri-
ate for the die. Having a pre-form
with a good structure reduces the
amount of material used and also
reduces the forming forces required
during forging. The die life is
improved.
Following die forging, the flash is tances of 4 m. Examples include hot
trimmed off and any required forging presses, piercing presses
piercing and coining work is and presses for partial forging of
performed on hydraulic trimming fittings and thick-walled pipes.
and calibrating presses. These
working sequences can either be
combined in one die or performed
consecutively in several stations.
Hydraulic forging presses are used
wherever high forces and long work-
ing travel distances are required.
This is revealed in numerous special
applications up to press forces of
300.000 kN and working travel dis-

OVERVIEW OF Hydraulic forging presses

Model MH 500 MH 800 MH 1000 MH 1600 MH 2000 MH 2500 MH 3000 MH 3500

Press force [kN] 5.000 8.000 10.000 16.000 20.000 25.000 30.000 35.000

Number of stations 1 – 3 1 – 3 1 – 4 1 – 4 1 – 5 1 – 5 1 – 5 1 – 5

Model MH 4000 MH 5000 MH 6000 MH 7000 MH 8000 MH 9000 MH 10000

Press force [kN] 40.000 50.000 60.000 70.000 80.000 90.000 100.000

Number of stations 1 – 6 1 – 6 1 – 6 1 – 7 1 – 7 1 – 7 1 – 7

Subject to technical modifications. Different tonnages are available upon request.

➔ APPLICATIONS
Hydraulic forging presses

• Fittings for pipelines

• Thick-walled pipes
• Rail ends
• Large flanges and brake disks (pre-forming)
• Crank shafts (calibrating)
• Axle parts (calibrating)

Hydraulic forging presses Systems for hot forging 49

 Systems for hot forging

Hydraulic presses for

forging ring blanks

MH series

WHETHER BIG OR SMALL, the depth of the product range

ROUNDNESS AND PRECISION ARE
THE MAIN CRITERIA.
The first forging operation when
manufacturing seamless rings is
forging ring blanks. Ring rolling lines
turn these into the precursors for
bearing shells, crown gears, flanges,
turbine disks for jet engines and var-
ious highly stressed structural ele-
ments.
and / or the required output rate.
Centering devices, swivel arms,
robots and manipulators guarantee
suitable parts and die handling.
THE ADVANTAGES Hydraulic press of the MH-series.
■ High forces for extremely large
parts

Hydraulic presses are particularly ■ High flexibility and high output

well suited for forging ring blanks:
High forces, long strokes and an
unlimited rated capacity are the fea-
tures needed for efficient ring blank
forging. Either highly flexible lines or
multi-station processes with opti-
mized output are used, depending on
rates
■ Proven press concepts
■ Different forging processes
adapted to the parts
■ Coordinated die processes,
in-house die and process
expertise

Ring blank progression.

Forging ring blanks with hydraulic press technology.

50 Systems for hot forging Hydraulic presses for forging ring blanks
 PROCESSES DEPENDENT ON THE
PRODUCT.
The required part geometry and a
suitable grain flow are provided by
different forging processes.
Ring blanks for simple parts are
manufactured open die upsetting fol-
lowed by pre-piercing and piercing.
Complex geometries are achieved by
forging and pre-piercing in a die.
Pre-piercing guarantees a symmetri-
cal grain flow in the part and has a
positive effect on the mechanical
properties of the finished product.
Each process requires a precisely adjusted or even varied during the
configured line with the necessary forging operation, such as adjustable
level of flexibility and the required profiles for the forging speed.
output rate.
The short cycle time of the press
allows the ring blank to be further
processed before it cools.
Different materials present the forg-
ing line with different challenges.
Low-alloy steels can be formed rela-
tively easily, while “exotic” materials
such as nickel-based alloys, Inconel,
titanium and aluminum alloys require
FEM simulation of symmetrical
process parameters that can be piercing on both sides.

OVERVIEW OF HYDRAULIC PRESS MODELS FOR MANUFACTURING RING BLANKS

Model MH 800 MH 1000 MH 1600 MH 2000 MH 2500 MH 3000 MH 3500 MH 4000

Press force [kN] 8.000 10.000 16.000 20.000 25.000 30.000 35.000 40.000

Number of stations 1 – 3 1 – 3 1 – 4 1 – 4 1 – 4 1 – 4 1 – 4 1 – 4

Model MH 5000 MH 6000 MH 7000 MH 8000 MH 9000 MH 10000 MH 12000 MH 14000

Press force [kN] 50.000 60.000 70.000 80.000 90.000 100.000 120.000 140.000

Number of stations 1 – 3 1 – 3 1 – 4 1 – 4 1 – 4 1 – 4 1 – 4 1 – 4

Subject to technical modifications. Different tonnages are available upon request.

➔ APPLICATIONS
Hydraulic presses for forging ring blanks

Seamless rings as the precursor for:

• Bearing shells
• Crown gears
• Flanges
• Blade carriers for jet engines
• Various highly stressed structural elements

Hydraulic presses for forging ring blanks Systems for hot forging 51
 Systems for hot forging

Hydraulic presses for

forging aluminum wheels

MH series

FORGING ALLOY WHEELS. Turnkey systems including the press-

Weight savings achieved in the
driveline are increasingly leading to
more energy efficient vehicles. In
addition, reducing the wheel weight
in trucks can allow for a payload
increase of up to 500 kg, depending
on the number of wheels, for the
same gross vehicle weight. In addi-
tion, the ability to polish the surface
to a mirror-like finish makes the
hearts of some truck drivers beat
faster.
These requirements are met by
forged aluminum wheels.
es, a saw for the billets, heaters,
automation and die change devices
make it easy to start forging alumi-
num wheels, or to extend an existing
production facility. Line controllers
make sure the complex systems
operate reliably.
THE ADVANTAGES
■ Concentrated high press forces
■ Proven press concepts

Hydraulic presses with high press ■ High precision and quality of

forged wheels
forces make it possible to forge alu-
■ High output rates
minum wheels with superior proper-
■ Forging processes adapted to
ties: Improved mechanical proper- Hydraulic press for forging
the part geometry aluminum wheels.
ties, lighter weight, good chemical ■ Complete lines from a single
resistance, and almost unlimited source
design options.

OVERVIEW OF HYDRAULIC PRESS MODELS FOR forging ALUMINUM WHEELS

Model MH 500 MH 800 MH 1000 MH 1600 MH 2000 MH 2500 MH 3000 MH 3500

Press force [kN] 5.000 8.000 10.000 16.000 20.000 25.000 30.000 35.000

Number of stations 1 1 1 1 1 1 1 1

Model MH 4000 MH 5000 MH 6000 MH 7000 MH 8000 MH 9000 MH 10000

Press force [kN] 40.000 50.000 60.000 70.000 80.000 90.000 100.000

Number of stations 1 1 1 1 1 1 1

Subject to technical modifications. Different tonnages are available upon request.

52 Systems for hot forging Hydraulic presses for forging aluminum wheels
 ADAPTED FORGING PROCESSES. Single or double-action presses
The design and geometry of the make it possible to forge the rim face
forged wheel, as well as the precisely. The surface is either left
required quantity, influences the type unfinished (as forged) or machined,
of system selected for production. depending on the quality required.
Simple wheel geometries without a
forged rim face, such as truck
wheels, are forged in one station.
The following station carries out the
trimming and flaring of the rim.
A similar process is used for small
quantities, in which the design of the
rim face is completed by machining.
For rims with a profiled face, press
lines comprising typically three to
four presses are used. The parts are
either forged with one heat in three
to four stations or with intermediate
Aluminum wheel progression.
heating.

➔ APPLICATIONS
Hydraulic presses for forging aluminum wheels

• Aluminum wheels

Hydraulic presses for forging aluminum wheels Systems for hot forging 53
➔ CASE STUDY
Systems for hot forging – hydraulic presses for forging aluminum wheels

THE CUSTOMER THE SOLUTION Both oil-based lubricants and water-

Supplier to automotive and truck
industries
THE REQUIREMENTS
Line for economical aluminum wheel
manufacturing for cars and pickups.
Schuler supplied two manufactur- based lubricants can be used. Part
ing cells, each based on presses handling inside the cell is done by a
with 70.000 kN press capacity. The six-axis robot designed for forging.
aluminum wheels are forged in one Short cycle times are achieved by
stroke. High-performance ejectors double grippers. Hydraulic clamps
are installed in bolster and slide to with internal cooling and a tandem
make sure the parts are unloaded die change cart are provided for
safely from the die. quick and safe die changes.
The wheels are then flared on a
press with 8.000 kN press capacity.
The proper operating conditions of
the dies are ensured by a lubricat-
ing and cooling system consisting
of lubricant conditioning device and
linear manipulator with rotary head.

Hydraulic press with 70.000 kN press capacity in production. Forged part and finished wheel.

2 3 4 2 3 4
1 Hydraulic forging presses
with 70.000 kN capacity each
2 Flaring pesses with 8.000 kN
capacity each
3 Robot with double-tooling
4 Lubrication manipulator with
rotating head
5 Die change cart

1 5 1

54 Systems for hot forging Hydraulic presses for forging aluminum wheels
Global service 6

Global service 55
 Global service
SERVICE – COMPLETE
PERFORMANCE
Technical services can play an
important role in achieving success
in the customer’s plant. We have
more than 900 service staff at work,
day-in and day-out, all over the
world. Services available include
procurement and project planning
through the production phase of the
lines. The core building blocks to
serve our customers include techni-
cal service for ensuring line availa-
bility, boosting performance by line
modernization and extensive training
courses for optimizing line utilization.
Complete technical services to ensure productivity and efficiency.
56 Global service
TECHNICAL SERVICE
■ Complete service
■ Maintenance and servicing
■ Preventative maintenance
■ Safety check on line for accident
prevention regulations
■ Spare parts and repairs
■ Energy checks
■ Machine relocation
■ Tele-service
PERFORMANCE ENHANCEMENT
■ Modernization
■ Machine optimization
■ Die and process technology
■ Pre-owned machines
TRAINING
■ Schuler Academy
■ Production support
On-site employee training by qualified trainers and start-up personnel.
Optimizing existing forging systems
can extend service life and improve
productivity. Our experience and
knowledge of the latest technology
and processes are continuously
channeled into efforts for improved
performance.

SERVICE FROM A SINGLE SOURCE

Modernization of existing lines can be an Schuler has more than 900 service staff at work,
economical alternative. day-in and day-out, all over the world.

Global service 57
i ADDRESSES
Global partners for forging technology
forging@schulergroup.com
www.schulergroup.com
GERMANY
Schuler AG
Bahnhofstr. 41
73033 Göppingen
Phone + 49 7161 66 -0
Fax + 49 7161 66 -233
Schuler Pressen GmbH & Co. KG
Bahnhofstr. 41
73033 Göppingen
Phone + 49 7161 66 -307
Fax + 49 7161 66 -729
Schuler SMG GmbH & Co. KG
Louis-Schuler-Str. 1
68753 Waghäusel
Phone + 49 7254 988-226
Fax + 49 7254 988-490
Röntgenstr. 16 –18
73730 Esslingen
Phone + 49 711 939-50
Fax + 49 711 939-5279
Schuler Automation GmbH & Co. KG
Louis-Schuler-Str. 1
91093 Heßdorf
Phone + 49 9135 715 -0
Fax + 49 9135 715 -159
Louis-Schuler-Str. 9
75050 Gemmingen
Phone + 49 7267 809 -0
Fax + 49 7267 809 -182
58 ADDRESSES
Gräbener Pressensysteme
GmbH & Co. KG
Wetzlarer Str. 1
57250 Netphen
Phone + 49 2737 962-0
Fax + 49 2737 962-100
Schuler Cartec GmbH & Co. KG
Bahnhofstr. 41
Schuler Group Headquarters, Göppingen
73033 Göppingen
Phone + 49 7161 66 -0
Fax + 49 7161 66 - 622
Gartenstr. 54
88250 Weingarten
Phone + 49 751 401- 03
Fax + 49 751 401- 2931
Schuler Cartec Engineering
GmbH & Co. KG Schuler SMG, Waghäusel
Heinrich-Hertz-Str. 6
88250 Weingarten
Phone + 49 751 4006 - 0
Fax + 49 751 4006 -195
Schuler Guß GmbH & Co. KG
Bahnhofstr. 41
73033 Göppingen
Phone + 49 7161 66 -890
Fax + 49 7161 66 - 616 Schuler SMG, Esslingen
Vögtle Service GmbH & Co. KG
Friedhofstr. 115
73054 Eislingen
Phone + 49 7161 9973 - 0
Fax + 49 7161 9973 -13
UmformCenter Erfurt GmbH
Schwerborner Str. 1
99086 Erfurt
Plant Umformtechnik Erfurt
Phone + 49 361 7066 - 50
Fax + 49 361 7066 - 51
Schuler Cartec Engineering, Weingarten
 Müller Weingarten AG
Schussenstr. 11
88250 Weingarten
Phone + 49 751 401-2211
Fax + 49 751 401-2694
Müller Weingarten AG
Plant Umformtechnik Erfurt
Schwerbornerstr. 1
Müller Weingarten, Weingarten
99086 Erfurt
Phone + 49 361 700
Fax + 49 361 706001
Schuler Service Deutschland
Am Weidenbroich 1A
Industriegebiet Bergisch-Born
42897 Remscheid
Phone + 49 2191 9519 - 90
Fax + 49 2191 9519 - 981
Schuler Automation, Gemmingen
TRAVIS Handelsgesellschaft mbH
Schussenstr. 11
88250 Weingarten
Phone + 49 751 401- 2762
Fax + 49 751 401- 2842
Schuler Automation, Heßdorf
Gräbener Pressensysteme, Netphen
Schuler Service Deutschland, Remscheid
FRANCE
Schuler France S.A.
17. rue Schertz, BP 26
67023 Strasbourg Cedex 1
France
Phone +33 388 657080
Fax +33 388 403490
Great Britain
Schuler Presses UK Ltd.
Brineton Street
Quayside Drive
Walsall, West Midlands WS29LA
Great Britain
Phone +44 1922 619-100
Fax +44 1922 619-101
italy
SW Italia S.r.l.
Via Erasmo da Rotterdam 4
10134 Turin
Italy
Phone +39 011 31-66511
Fax +39 011 31-99237
SWITZERLAND
Beutler Nova AG
Hofmatt 2
6142 Gettnau
Switzerland
Phone +41 41 9727575
Fax +41 41 9727576
SLOVAK REPUBLIC
Schuler Systems & Services GmbH
& Co. KG
Service Slovak Republic
Dukelská štvrt’ 948 /11
01841 Dubnica nad Váhom
Slovak Republic
Phone +421 42 286 1341
Fax +421 42 281 2002
ADDRESSES 59
i ADDRESSES
Global partners for forging technology

SPAIN BCN Technical Services, Inc.

1004 East State Street
Schuler Ibérica S.A.
Hastings, Michigan 49058
Edificio SCV Forum
USA
Planta 2a, Puerta 4a
Phone +1 269 9483300
Ctra. Sant Cugat-Rubi, Km 01,
Fax +1 269 9483310
no 40 – 50
08190 Sant Cugat del Vallès
MexiCo
(Barcelona)
Schuler Presses UK Ltd., Walsall, Great Britain
Spain Müller Weingarten de México,
Phone +34 93 54423-00 S.A. de C.V. Puebla
Fax +34 93 54423-01 Lateral Arco Norte Km. 25 # 4
San Francisco Ocotlan
RUSSIA C.P. 72680 Puebla, Pue.
Mexico
Müller Weingarten AG
Phone +52 222 4310019
Moskau Representative Office
Fax +52 222 4310018
Prospekt Wernadskowo 103,
Korpus 2
Müller Weingarten de México, Beutler Nova, Gettnau, Switzerland
119526 Moskau
S.A. de C.V. Saltillo
Russia
Calle Automotriz # 3065
Phone +7 495 4332309
esquina metalmecánica
Fax +7 495 4342363
Parque Industrial Saltillo-Ramos
Ramos Arizpe, Coahuila.
CZECH REPUBLIC
C.P. 25900
Müller Weingarten Ceská Republika Mexico
Mořkov Phone +52 844 4885947
Životice u Nového Jičína Č. p. 118
Müller Weingarten, Morkov, Czech Republic
74272 Mořkov BraZIL
Czech Republic
Prensas Schuler S.A.
Phone +420 556 779 -911
Av. Fagundes de Oliveira, 1515
Fax +420 556 779 -904
09950-904 Diadema, São Paulo
Brazil
USA
Phone +55 11 4075-8444
Schuler Incorporated Fax +55 11 4079-2766
7145 Commerce Boulevard
Canton, Michigan 48187
Schuler France, Strasbourg, France
USA
Phone +1 734 2077200
Fax +1 734 2077222

Schuler Iberica, Barcelona, Spain

60 ADDRESSES
 China Schuler Sales & Service Co., Ltd.
Branch Office Jinan
Shanghai Schuler Presses Co., Ltd.
Unit 35A15/34F
750/8 Luo Chuan Zhong Road
Yinhe Building No.168 Jingqi Rd
Shanghai 200072
Jinan 250001
PR China
PR China
Phone +86 21 56650081
Phone +86 531 82079948
Fax +86 21 66529060
Fax +86 531 82079948
Schuler Incorporated, Canton, MI, USA Tianjin SMG Presses Co., Ltd.
Yinfeng Huanyuan A 1004 INDIA
Youyi Bei Road 65 Hexi District
Schuler India Pvt. Ltd.
Tianjin 300204
401 – 403 Keshava,
PR China
Bandra-Kurla Complex
Phone +86 22 83280895
Bandra (East)
Fax +86 22 83280540
Mumbai 400 051
Schuler Sales & Service Co., Ltd. Indien
750/8 Luo Chuan Zhong Road Phone + 91 22 66800300
BCN, Hastings, MI, USA Shanghai 200072 Fax + 91 22 66800399
PR China
Müller Weingarten AG
Phone +86 21 56650081
Liaison Office India
Fax +86 21 66529060
Unit 204, 2nd FloorSuyash Classic
Müller Weingarten (Dalian) 75 + 75/2 Baner Road Baner,
Forming Technologies Co., Ltd. Pune 411045
No. 1 Weingarten Road Indien
Dalianwan, Ganjingzi District Phone + 91 94 440-79263
Dalian 116113
Prensas Schuler, São Paulo, Brazil PR China
Phone +86 411 87124002
Fax +86 411 87609916

Schuler AG Beijing Representative

Office
Room 1012 Talent International
Building
No. 80, Guangqumennei Dajie
Chongwen District
Shanghai Schuler Presses, Shanghai, China Beijing 100062
PR China
Phone +86 10 51696769
Fax +86 10 51696768

Müller Weingarten Forming Technologies,

Dalian, China
ADDRESSES 61
 Put it into motion. Forging with Schuler.
Your notes

62
63
 The entire world of forging
The entire world
of forging
400E-102009-WSP-2000 Copyright by Schuler

Schuler PRESSen GMBH & CO. KG Schuler SMG GmbH & Co. KG Müller Weingarten AG
Bahnhofstr. 41 | 73033 Göppingen | Germany Louis-Schuler-Str. 1 | 68753 Waghäusel | Germany Schussenstr. 11 | 88250 Weingarten | Germany
Phone + 49 7161 66-307 | Fax + 49 7161 66-729 Phone + 49 7254 988-226 | Fax + 49 7254 988-490 Phone + 49 751 401-2211 | Fax + 49 751 401-2694

forging@schulergroup.com | www.schulergroup.com