Press openwork 7. Review of machines for cold forging openwork. Machine "Azhur-Universal" rolling and bending

Machine tools of the "Azhur" series are designed for artistic forging of metal in a cold way. The cold forging method allows you to make many decorative details. Work on the machines of this line is safe, efficient and does not require special long-term training of personnel.

Cold forging capabilities

The cold forging method is a torsion and bending of rods of a certain section. The result is a set of parts from which the finished product is assembled.

Specialized machines "Azhur" allow you to perform the following operations:

• bending elements according to the template by rotation. This procedure is carried out using special templates compatible with the spindle. The role of the machine is to control the accuracy of the corners;
• the twisting of the bar takes place on a machine of the same type with additional nozzles included in the package;
• coiling of rings is carried out on a special nozzle;
• cutting of forged parts is carried out on machines of a special type - scissors. The sections of the part are displaced relative to each other, creating an even, neat cut.

Now more about the machine "Azhur" of each model.

Machine "Azhur-1M" bending

machine "Azhur-1M"

It can produce almost any popular elements used in artistic forging products:

• baskets;
• volutes;
• rings;
• peaks;
• reverse bends;
• endings;
• torsion bars;
• snails.

The power of the machine is 3000 W, it works from networks of 220 or 380 V. "Azhur-1M" works with workpieces with a diameter of 8 to 16 mm, a profile pipe No. 15 and No. 20. Torsion bars are made of 10-20 mm rod. The working shafts rotate at a speed of 7.5 revolutions per minute.

Additionally, the machine "Azhur" is equipped with:

• a power unit that operates as a drive to the forging module;
• horn for heating the ends of the bar;
• forging module with a set of eccentric rollers. With its help, the ends of the rods "goose foot", "faceted peak", "dome peak" and others are formed;
• a drum for making a “ring” part with a diameter of 114 mm from a round or square rod from 6 to 12 mm;
• snail - used to make curled elements from a profile pipe, round or square rod. Completely eliminates the appearance of creases;
• torsion - used to perform the element of the same name, comes in a set with washers and adapters.

The machine includes an electrical part, a mechanical part and a horn. Mechanical elements:

• electric motor;
• bed;
• forging module;
• reducer;
• tooling.

The electric motor through the gearbox drives the lower roller of the forging module. From here, the movement goes to the upper and middle rollers. Eccentrics are placed on these shafts; during torsion, they bend the workpiece into the required shape. The workpiece is preheated.

Some elements are created using a drum or “snail” installed on the middle shaft. To create a "torsion bar" and "basket" devices are installed on the upper roller. The heating horn is powered by a gas burner.

Machine "Azhur-2" rolling

machine "Azhur-2

The purpose of "Azhura-2" is to apply a convex ornament to a profile pipe, strip, square and round bar. The power of the electric motor is 3000 W, it operates from a three-phase network of 380 V, it can be modified for 220 V. The equipment rolls up to 4.5 linear meters per minute.

The maximum size of the workpiece in cross section, in mm:

• profile pipe 40 x 40;
• stripes 20 x 20;
• round bar diameter 20;
• side of square 20.

The shafts rotate at up to 7.5 revolutions per minute. There are two complete sets of the machine: basic and full.

The basic package includes:

• forging module;
• power unit;
• top and bottom shafts;
• gear cage with adjustment - necessary for the simultaneous rotation of both shafts at any position of the upper one;
• guiding mechanism for the strip;
• guide mechanism for the square;
• rollers for rolling cuts in the shape of a square;
• rolling textured rollers;
• "Greek" ornament for the strip.

The complete set additionally includes:

• 37 types of rolling reliefs;
• 7 sets of shafts for rolling different reliefs on a profile pipe, square;
• horizontal straightening mechanism;
• smooth adjustment of rolling speed.

Rolling machine "Azhur" consists of the following elements:

• electric motor;
• frame welded from steel;
• gearbox with gears;
• forging module with straightening mechanism;
• electrical part.

The motor, through a gearbox with gears, supplies rotational motion to the shafts of the forging module. Here are the forming rollers. The bar passes between the upper and lower rollers and takes on the shape of the rollers. After that, the part is fed to the dressing mechanism: two balancers, which give the part a flat or curvilinear shape.

Machine "Azhur-Universal" rolling and bending

machine "Azhur-Universal"

This model is a combination of the two previous machines "Azhur-1M" and "Azhur-2", which allows you to create almost all known forging elements, process edges, roll ornaments on parts of different profiles.

The machine is offered in two trim levels: basic and complete. It works with blanks from 8 to 20 mm in diameter, strips up to 60 mm wide. The working shafts rotate at a speed of 8.5 revolutions per minute. The equipment is equipped with a 3000 W motor powered by a 380 V three-phase network. The machine is designed to work in small and medium-scale production.

Mechanical elements of the rolling and bending device "Azhur-Universal":

• electric motor;
• bed;
• two forging modules;
• reducer;
• electrical part.

Through a belt drive, the electric motor transmits the movement to the gearbox and rollers of both forging modules. Eccentrics are located on the middle and bottom rollers of the first forging module, they make parts in the form of a "blade", "spike", "houndstooth". A “snail” is attached to the outer part of the middle roller. With the help of a combination of the console and the upper roller, "torsion bars" are made.

Press horizontal "Azhur-3M"

hydraulic press "Azhur-3M"

The hydraulic horizontal press "Azhur-3M" is designed for making metal fences, gratings from a rod with a diameter of up to 20 mm, strips up to 20 mm wide. Designed for use in large-scale production.

Electric motor power 5500 W, rotational speed - 1450 rpm. Works from a three-phase network 380 V. The press creates force in 30 tons. Attached to it is equipment for making patterns: “wave”, “cartouche”, “corner”, “semicircle”, “French profile”, “yeshka”, “chervonka” and others.

The press consists of the main elements:

• base;
• gear hydraulic pump in tandem;
• electromechanical hydraulic valve equipped with a safety valve;
• hydraulic tank;
• hydraulic cylinder;
• stamp with guide columns;
• oil filter;
• electrical panel.

Engine oil 403, Shell Tellus 46 is used as a working fluid. The pump assembly is protected from overloads by a safety valve. The press is installed on a hard surface made of asphalt or concrete, set horizontally according to the level.

Machine for twisted pipe "Azhur-4"

machine "Azhur-4"

On this machine, it is possible to produce twisted pipes with a diameter of 10 - 160 mm, with a given coil angle. Such an element decorates the finished product very much, it is used as a stand for a lantern, furniture, fences.

The machine produces up to 4 linear meters of twisted pipe per minute. It is equipped with a 3300 W electric motor powered by a three-phase power supply. The speed of rotation of the shafts is 18 revolutions per minute.

On the base there is a base plate with grooves (3 pcs.) located at an angle. Sliders (3 pcs.), equipped with movable brackets, are attached to the base plate. Rulers are placed on the back surface of the plate to control the movement. Each bracket is equipped with swivel plates, which rotate along the axes relative to the bracket. You can set the position of the plate using the clamp.

Rotary plates are equipped with rollers on bearings, an electric motor with a gearbox. The transmission of motion is carried out through a cam-type clutch. In the steady rest, cartridges for pipes of various sizes can be changed.

Pipe bender "Azhur-6"

machine "Azhur-6"

The three-roll machine is designed for profile bending and rolling along the radius, it works with pipes with a diameter of up to 80 mm, a strip of up to 100 mm, channels no larger than No. 12, an angle up to No. 63. Bending in horizontal and vertical planes is possible. The power of the electric motor is 1100 W, it operates from a three-phase power supply network 380 V. The rolls rotate at a speed of up to 11 meters per minute.

Cold forging is a very popular form of metalworking. It does not require many years of mastering the art of a blacksmith, the equipment of a bulky, traumatic and fire hazardous traditional forge. Consider machines for cold forging metal Azhurstal.

Rolled metal is formed in an unheated state by applying pressure. Many novice home craftsmen make cold forging devices on their own. This is fully justified at the stage of mastering the technology, making decorations for your home and site, and analyzing the market.

But if you decide to start a business in this area, then it is better to think about purchasing industrial cold forging equipment.

Cold forging capabilities

The cold forging method is based on the physical phenomenon of plastic deformation of a metal workpiece under the force applied to it. The workpiece is bent, stretched, twisted, flattened or cut, acquiring the shape desired by the master.

Forged rocking chair

Using this forging method, do:

• rods and lattice decorations;
• decor elements;
• decorations for landscape design;
• furniture details.

Based on standard elements, passionate craftsmen are constantly developing new designs for their products.

Types of machines Azhurstal

Artistic forging machine "AZHUR-1M"

Machine tools manufactured by Azhurstal are divided into several types:

• Universal bending machines for cold forging openwork allow you to make curls, volutes and almost all figures used in artistic forging.
• Rolling machines are designed to form a relief pattern on the edges of a bar or shaped steel, as well as to produce a coiled pipe with a variable coil pitch.
• Vertical and horizontal presses developing forces up to 100 tons.
• For preparatory operations: a cutting machine for cutting solid and profiled rolled products and a machine for transverse cutting of rolled metal.

Machine for artistic forging "Azhur-3M"

Azhurstal can, at the request of the customer, complete universal machines:

• portable forges for heating the ends of the blanks when performing complex elements;
• a large number of special equipment - snails, rollers, mandrels, etc.

Artistic forging machine "Azhur-1"

This allows you to expand the capabilities of the equipment or increase the maximum size and complexity of the manufactured elements.

Manufacturing technology of openwork forging on the machine

The technology for the production of products on the Azhurstal machine for artistic forging captivates with its simplicity. The designers of the enterprise did everything to facilitate the work as much as possible and achieve high quality.

Most of the machines are equipped with automation, and for the production of a curl or volute, the user just needs to install the appropriate equipment, set the dimensions, fix the workpiece and press the feed button. The Azhurstal machine itself regulates the feed and pressing force of the forming rollers and will stop at the end of the operation.

Pros and cons of technology

The main advantages of cold forging technology are:

• Ease of use. There is no need for long training.
• Low labor intensity.
• Identity of received serial products.

In addition to the advantages of the method, there are also disadvantages.

• Limited product options. It is impossible to forge a flower or a leaf, not to mention figurines.
• The limited form of blanks is a bar, strip, hollow rolling.

The method is perfect for the production of small and medium series of the same type of parts.

Necessary materials

The list of materials used for cold forging includes

• The rod is round.
• The rod is square.
• Tubes are round or square.
• The strip is metal.
• Profiled rental.

In addition, you will need:

• grinder or cutting machine for cutting blanks to size;
• welding machine;
• metalwork tools - vise, clamps, hammers, tongs, etc.

In the workshop or under a canopy, you need to equip a spacious, level place for assembling elements into a finished structure.

Features of maintenance of machines for openwork forging

Machine tools produced by Azhurstal are distinguished by their reliable design and high resource. In order for the unit not to fail during the execution of a responsible order, it is necessary to follow the regulations for its maintenance.

Daily maintenance consists of an external inspection for the absence of mechanical damage and checking the tension of the drive belt, as well as the reliability of fixing the equipment and the executive bodies of the unit.

Every 1,000 hours of operation, the gears and bearings should be checked for lubrication, and if the lubrication is worn out or hardened, re-lubricate. It is also necessary to check the oil level in the transmission and add it if the level is below the mark. At the same time, the safety of the wiring and all electrical equipment should be checked.

In the presence of a large fleet of equipment, it is possible to conclude agreements on maintenance and repair by authorized Azhurstal dealers

Features of various machine models

Azhurstal offers a wide range of equipment and accessories for all manufactured units.

The product line begins with the compact "Azhur-mini". Despite the low power - 1.1 kW and modest dimensions, it copes with a bar up to 16 mm. This is a great choice for the beginner.

The Azhur-1 station wagon has three times more power and a wider choice of additional equipment and accessories for it. It is already designed for professional use and allows you to produce up to 5000 bent elements per month.

Rolling machine "Azhur-2" is designed to form a three-dimensional pattern on the strip, round and rectangular rolled products.

Universal "Azhur-universal" combines both bending and rolling unit. This is already a small technological complex that can significantly save working time.

In addition to them, "Azhur-4" is also supplied to obtain a twisted pipe with a different pitch of turns.

The presses are produced in three versions: horizontal "Azhur-3", vertical "PV-100" and vertical forging press - "Azhur-7". They are equipped with an electromechanical or hydraulic drive and develop a working force of up to 100 tons.

Azhurstal equipment covers almost all conceivable needs of manufacturers in the field of openwork forging.

"Azhur-1M" - a set of equipment designed for professional forging, the machine allows you to perform the main elements of artistic forging.

By purchasing a machine, you will receive the following forging options:
- Smooth "paw"
- "Paw" with a double-sided pattern
- Forged endings №1,2,3,4
- Faceted Pike
- Elements "curl" and "volute"
- Torsion bar "longitudinal twisting"
- Volumetric "basket", as well as arcs of the ring of various angles and diameters.

So you can purchase additional equipment for the Azhur-1m artistic forging machine at a low price, expanding its capabilities and simplifying work. For example, an electromechanical drive, metal heating, a bending block (which allows metal to be bent in the required radius), profile bending rollers, profile pipe rolling rollers and a tight curling device. As well as CNC (computer numerical control), which will automate production and perform work with computer precision.

Having bought the Azhur-1M art forging machine at the manufacturer's price, you will receive a reliable and unpretentious device, which, in addition to its low energy consumption, is highly productive, which is important in production, because high performance will quickly pay for the investment and you will reach absolute profit.

When purchasing a machine, we are pleased to offer you an additional range of services for your comfort, for example, we will deliver the purchased machine to the Transport Company. We give a guarantee for the machine for 3 years. We have a service center where our experts will help you solve any issues. We can also offer you a machine for leasing, i.е. you don't have to save or borrow money for a machine, you buy a machine, start working and pay for the machine.

	AC-1 power unit Serves as an electromechanical drive to the forging block and other devices
	Horn A1-2 To warm up the endings in the manufacture of goose foot, domed, faceted peaks, etc.
	Forging block A-1 Designed to work with interchangeable nozzles. The block includes rollers A1-3 for forming ends: "goose foot", domed, faceted peak, etc. (two drawings included) from a bar 10-16 mm. Delivery of the forging block without rollers is possible.
	Additional rollers A1-3 For the manufacture of houndstooth endings, domed, faceted pikes, various types of forged endings
	Nozzles - drums Drum for winding rings 50 mm - A1-8 Drum for winding rings 70 mm - A1-8 Drum for winding rings 90 mm - A1-8 Drum for winding rings 114 mm - A1-8 Drum for winding rings 125 mm - A1-8
	Nozzles - Snails for making chervonka, comma and volute For elements with unshaped end - BL For elements with the ending "goose foot" B1, M1, M2, M3 For elements with the ending "tight curl" - T1 For elements with the “reverse bend” ending - No. 1-5 For bending from a prepared profile pipe - U2 For the element "Roman curl" - BM
	Nozzles - rollers For preparation of a profile pipe 15x15, 20x20 - A1-20 For the preparation of a profile pipe 25x25 - A1-21 For the manufacture of clamp strip 20x1.5, 20x2 A1-17
	Nozzles - for twisting Device for the manufacture of "torsion" - A1-16 Device for the manufacture of "baskets" - A1-14
	Profile bending machine А1-18 For bending square pipes up to 40x40, bars up to 40x40, strips up to 100x20, round pipes Ø42 mm and Ø76 mm. Add. Set of rollers for channels up to No. 12 and angles up to 63x63