Press and Forging
Pressing & Forging Metalock Onsite Repairs
Our engineering challenge in supporting you…
The pressing and forging industry equipment has to deal with particularly harsh operating
conditions. This takes it toll on the equipment and operators, the resulting metal fatigue could
result in fracture or breakage of the parent metal.
A characteristic of this industry is that any stoppages cannot be tolerated, due to the high cost
of loss of production. It is with this in mind that MIA members are skilled in the use of the
Metalock process to repair pressing and forging equipment onsite. Repairs are challenging,
due to the nature of the working conditions and the size and design of the plant, but this is not
the case for Metalock. The Metalock process allows for the immediate diagnosis of the
damage, where many of the repairs can be carried out onsite with little or no dismantling.
Where the downtime is expected to be weeks, a Metalock repair can bring operations back in
hours or days, especially when using other members technicians to speed up the repair.
In addition to speed of repair, many press tools can be repaired in stages to allow for
production to continue during the repair procedure.
Our engineering members have been working in pressing and forging for decades, and have
built up solid relationships with customers based on our excellent turn-around capabilities and
understanding the needs of the customer.
Some of the repairs our members carry out include:
All types of power presses
Hot and cold forging presses
Rams and con rods
Press tools & dies
CASE STUDY – “C” PRESS
1. An all too frequent cause of this type of failure to the simple C type presses, is the overloading and general misuse by operators over prolonged periods. Often the press is part of the production line and this absence creates havoc to the production flow, thus making its immediate replacement imperative. However, many of these presses are over 20 years old, and replacement parts are not available. The cost of these, and down-time, also becomes an important factor.
2. With a 24 hour phone call to the head office, a Metalock member engineer had commenced his survey of the damage. The fractures followed a very familiar pattern and the estimate of time, cost, and method of approach was quickly completed. With existing special fixtures and clamps being available, it was possible to commence the repair immediately, repositioning the beroken pieces and realigment.
Three metalock engineers were assigned to the repair, which was to be completed within five days. A copy of the survey, which also contained details of the estimated cause of damage, was presented to the Production engineer.
3. The repair was commenced a mere five hours after the damage occured. Little dismantling was necessary to facilitate the repair. The total length of the fractures amounted to 775 inches. The engineers survey also called for the Masterlock inserts to be placed in areas of greatest stress. The careful realignment obviated any need to remachine, even on the slideways. Furthermore, the Metalock engineer made a promise that the press would be as strong after the repair as it was prior to the damage.
4. The repair was completed in 150 man hours over a period of four working days. Not only was the repair guaranteed, but by the introduction of stiffeners the press is now in a much better condition to withstand the operator misuse it may be subjected to. Management had also been made aware of the original cause of the damage.
Total Metalock costs were one-fifth of the cost of replacement.
CASE STUDY – WORKING LIFE OF 250 TON PRESS EXTENDED
The photographs show the extent of the fractures suffered by this 250 ton press. Periodical overloading and lack of regular servicing and maintenance during its long working life, all combined to cause the total splitting of the nut casing and cracks to the lateral frame pillars. Complete replacement of the press, or the acquisition of a new body was not considered viable, since existing customer contracts had to be fulfilled within a specified time frame. Metalock were contacted and asked to inspect the machine and advise if a repair was possible.
Metalock agreed to carry out the work which comprised repairs to fractures totalling 110 inches, necessitating the use of 250 Metalock keys and 4 Masterlocks —although it was pointed out that the working life of the press would possibly only be extended by approximately 30 days. This, however, would allow the client to fulfil their existing contracts. Following its recommissioning the press has now worked at full capacity for over 6 months, illustrating the durability of the Metalock repair process. – Metalock member, Italy