Ernst Müller (Auth.) - Hydraulic Forging Presses-Springer Berlin Heidelberg (1968)

Hydraulic Forging Presses
Hydraulic
Forging Presses
By
Ernst Miiller
Duisburg
With 225 Illustrations
Springer-Verlag Berlin Heidelberg GmbH

ISBN 978-3-662-01 166-9 ISBN 978-3-662-01164-5 (eBook)
DOI 10.1007/978-3-662-01164-5
Al! rights reserved, especially that of translation into foreign languages

It is aho not permitted to reproduce this book, either whole or in part, by photomechanicalmeans
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without written permission from the Publishers
© by Springer-Verlag Berlin Heidelberg 1968
Originally published by Springer-Verlag, Berlin· Heidelberg in 1968
Library of Congre5s Catalog Card Number 67-15615
Softcover reprint ofthe hardcover Ist edition 1968
The reproduction of general descriptive names, trade names, trade marks, etc. in thig pUblication,
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Imderstood by Trade Marks and Merchandise Marks Law, may accordingly be freely use(l by anyone.
Titei Xr. 1346

Preface
This book "Hydraulic Forging Presses" is a translation of volume I,
third revised edition, of the German series of books "Hydraulische
Pressen und Druckfiussigkeitsanlagen". The English version of the third
volume about rod and tube extrusion presses for metal and cable works
was published in H)61.
In order to facilitate reading, all formulas, terms and dimensions
used in this book have been adapted to English usage, except for ex-
tracts from German standards.
1 am especially grateful to MI'. C. W. FINKL, Chicago, for his many
valuable suggestions and his painstaking work in proofreading the trans-
lation.
Furthermore, 1 should like to thank the publishers for their kind
cooperation and excellent presentation of the work. 1 extend my thanks
also to Mr. ALBERT HERTL and to the translator, Mr. HEL1\HJT FUCIfS,
for their work from the technical and organizational viewpoints.
Duisburg, June 1968

Erost Miiller
Contents
INTRODUCTION .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PRINCTPLES OF FORGING P}{ESSE~ ............................... 2

a) Press Loads .................................................. 2
b) lngots and Forging Die~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
e) Pressure Fluids ............................................... (i
d) Kinds of Drive ............................................... 8
e) TypeR of Constructioll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Il
CHAPTER 1: FORGIXG PRESSE~................................... 1:3

a) Forging Presses of Moving.Crosshead Design. . . . . . . . . . . . . . . . . . . . . . 1:3
1. RoHom or Base Platens ..................................... 1:)
2. Cylinder Platens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2;)
3. Columns and Nuts .................................. " .. ..... :W
4. Press Cylinders and Ramr; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. :38
,). :Vloving Crossheads .......................................... I)(i
6. Return Deviees ............................................. H:3
b) Forging Presses of PuIl·down Design ............................ (\(i
e) Forging Presses of Single.Frame Design. . . . . . . . . . . . . . . . . . . . . . . . .. 72
CHAPTER II: PImSSURE FLUlD INi-lTALLATIONS FOR FORnINC

PRESSES ..................................................... . 7fi
a) Pumps ...................................................... . ,fi
1. \Vater.Hydraulie Pressure Pumps ............................ . 78
2. Oil.Hydraulic Pressure Pumps ............................... . !)l
b) Intensificrs .................................................. . 98
1. Steam- and Air Intensifiers .................................. . !10
2. lVrE'chaniealintensifiers 107
C') Aecumulator Installations ..................................... . 114
1. Aecumulators .................. ..................... . ... . 113
2. Pumps ................................................... . 120
:3. Auxiliary Equipment ....................................... . 12:3
d) Hydraulic Line Systems ...................................... . 1:31
1. Air V E'ssels ................................................. . 131
2. Tanks, Coolers and :Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13(i
3. Piping and Shutoff Devices ................................. " 140
CHAPTER III: CONTROLR FOR FORCmm PRERSES ................ 148

a) Control Gears ............................................... " 148
b) Controls for Accumulator-Operated Forging Presses ............... 171)
e) ControIs for Steam- and Air-Hydraulie Forgillg Prcsses ............ 17S
CONTENTS VII
d) Controls for Forging Presses with Direct Pump Drive .............. 182
e) Controls for Forging Presses with Mechanical Intensifier .. . . . . . . . . .. 183
f) Controls for Hydraulic Auxiliary Devices . . . . . . . . . . . . . . . . . . . . . . . .. 186
g) Hydraulic Circuit Diagrams of Carried-out Forging Press Installations 187
h) Indicating of Forging Presses ................................... 192
CHAPTER IV: EXAMPLES OF DESIGN AND CALCULATION ........ 195

a) Examples of Design ........................................... 197
1. Press Cylinder with Filling Valve ............................. 197
2. Steam Return CylindC'r and Piston ............................. 197
3. Moving Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 197
4. Base Platen ................................................. 197
b) Examples of Calculation ........................................ 197
1. Main Cylinder .............................................. 197
2. Prefill Valve with lntensifier ................................. 202
3. Shifting Table and Ejecting Device . . . . . . . . . . . . . . . . . . . . . . . . . . .. 202
4. Steam Intensifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 204
5. Hydraulie Intensifier ........................................ 20;;
6. Cylinder Platen ............................................. 20(}
7. Columns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 207
8. Air Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 208
9. Power Water Station ........................................ 210
CHAPTER V: ECONOMY ANDCOMPAR1S0NOFTHEVARIOUSKINDS
OF DRIVE FOR FORGING PRESSES ............................ 211
a) Steam- and Air-Hydraulic Forging Presses ....................... 211
b) Forging Presses with Accumulator Operation ..................... 21(\
e) Direct-Driven Forging Presses .................................. 220
CHAPTER VI: AUXILIARY MACHINES "FOR FORGING PRESS
INSTALLATIONS ......•........................................ 224
a) Forge Cranes ................................................. 224
b) Rotating and Gripping Devices ................................. 229
e) Forging Manipulators ......................................... , 231
d) Auxiliary Tools ................................................ 241
CHAPTER VII: CLOSED-DIE FORGING PRESSES . . . . . . . . . . . . . . . . . . .. 243
a) Closed-Die Forging Presses for the Deformation of Steel ............ 24G
b) Closed-Die Forging Presses for the Working of Light Metals ........ 25(;
LOCATION AND MANUFACTURER OF LARGE FORGING PRESSES .. 269
INDEX ............................................................ 273
LIST OF TABLES .................................................. 279
INTRODUCTION
Hydraulic presses for manufacturing open-die and die forgings,
briefly caUed "hydraulic forging presses", are built in various types.
The same operating characteristic holds true for aU of them, which,
contrary to forging hammers, is based on the static effect of the press
Ioad where the forces are contained within the press proper while hammer
operation creates dynamic forces that are transmitted to the foundation.
The hydraulic press consists of the press frame to take up the flux
of force, the main cylinder 01' main cylinders with their rams, the
return cylinders, and the construction parts for mounting the stationary
and movable dies. In addition, depending on application and working
conditions of the press, also slides for the dies and tools as weU as ejecting
devices are used. The hydraulic power station, the controls and the
piping with vessels and gauges complete the press installation.
The press load equals the product of ram area multiplied by
hydraulic pressure. Among aU possible forms of pressure transmission,
the utilization of the hydraulic pressure requires the minimum expensc
for construction and wear parts. For large press Ioads, therefore, only
hydraulic presses are used.
The working speed of the piston corresponds to the hydraulic fluid
volume fed per unit time into the working cylinder. The type and size
of the hydraulic power station are chosen depending on the required
maximum working speed for the various forging operations, and the
pipe and valve diameters are dimensioned so as to keep the unavoidable
flow losses within bearable lirnits. Especially large flow areas are required
in case of high advance and return speeds due to low hydraulic pressure
for filling and emptying the main cylinders.
Considering the switching periods, the ram velocity determines a
certain number of strokes per minute. The upper lirnit of the strokes per
minute are set by the efficiency of the ingot handling equipment.
The sequence of single movements is controlled by analogous acti-
vating of the control gear and necessitates close co-operation of the
operating team. Automation of control steps for repeating press cycles
has also been applied in the field of forging presses in order to relievc
the workers and to increase efficiency and forging accuracy.
1 Miiller, Hyllraulie Forging l'rcsses
2 PRINCIPLES OP FORGING PRESSES
PRINCIPLES OF FORGING PRESSES

a) Press Loads
The required load of a forging press is determined by practical
experience and rough calculations 1 ) ; the governing factors are the cross-
section of the largest ingot
and its material character-
istics at forging temper-
ature. Usually, the overall
dimensions and the weigh t
Table 1. Weights and Dimwsions of J ngots of the ingot are indicateel
by its cross-section (see
In 'o l Weighls
lhş .
a Dia. b ])ia.
in. "
in.
table 1). The ingot cross-
section must be determineel
2,530 1
14 /4 16 /
1 41 by the larg est forging to be
5,280 18'/8 21 47 made by the press where ,
11,000 24 1/2 28 58
22,000 32 36 68 depending on the require-
66,000 47 1/4 531/4 96 ments to the forging, a
99,000 54 61 J04
117 forging ratio of two to six
143,000 60 69
209,000 68 1/ 2 78 132 is eligible. The forging ratio
275,000 77 63 ,/ 4 139 is the ratio of the ingot
330,000 83 92 1/2 140
440,000 96 108 146 cross-sectional area to that
of the finished forging .
Overall dimensions of ingots as a function of forging cross-sectional
are a and forging ratio may be easily taken from graphs (fig. 1).
For calculating the press load, the following formula is applicable: -
where
A", = effective working arca,
s, = mean tensile strength,
ed = efficiency of deformation.
The size of the effective working area Aw elepends on the forging

01'upsetting operations involved.
By mean tensile strength St we mean the high-temperature stability
of the material eorresponding to the forging temperature and operating
speed; this high-temperature stability is knowll through test reslllts.
1) SIEBEL, E.: Die Formgebung im bildsamen Zustande, Diisse ldorf: Verlag

~tahleisen 1932. - SIEBEL, E.: Stand der wissenschaftlichen Erkenntnisse bei der
Warmformgebungund dem Schmieden. Stahl u. Eisen 76 (1956) H. 7. - MEYER, H . :
Zahlenwerte uber die Umformfestigkeit von unlegierten und legicrten Stiihlen nach
neueren Schrifttumsangaben. \Verkstattstechnik u. Maschincnbau (~chmicde
technischc Mitteilungen) 48 (1958) H. 12.
PRESS LOADS 3
The efficiency of deformation ea takes into account the losses by
friction between work piece and anvil and the intern al flow resistances
which depend to a large extent on the kind of deformation. The efficiency
is, therefore, grea tly varia bIe and can, in most cases, not be given as binding.
lngo!
Ho/slodr lIf!ig/Il
Cross Oio- forging ralio 010- :;:;
mefer wllh- wifh ~
sec/ilJn mekr 0111 head ~
6 I "Oi head
3 If S 11<::
",g, K9 Kg
cm.z mm TIUTI.
188 1200 1600 1.100
178 1350 1980 1'IIJ0

300- 2 19 11 2000 2800 1600
'100- eZ Il Z7S0 .%00 1S70

- tll e '1900 6190 2200
500- 2Jj ZSJJ 9700 12000 '1Z00
600-
I
700- /' t9 JJ 6'11JO 8000 1800
300 v
80f}-
900- 3SJ 3'1 JJ 7800 10'100 18S0

1000- 36 JJ 11000 18000 ZSSO
W)"
'IO./l 18000 18S00 2350
'15(J '1'1 11 17000 2/i300 2700
5U,
2000- JO./l 31500 Z/iSIi
53i
S. 55 JJ 31230 1850
JOOo-
§.f0
WJOo- 700
73i
SOOO- 8f)J
850
6000-
90(J
7000- 9S,
18{JfJo 110nn
3 If S
'Fig. 1. Ingot gizes ao a fllllction of cross-scctional arca of ftnished work piece and its forging rat.io.
It is for this reason that usually the deformation resistance Rd = 8,

e,z
is used for caIcuIating the press Ioad, which has been obtained by
upsetting tests (see fig. 2). According to this graph, a forging tempel'ature
1*
4 l'RIl\CIPLES OF FORGING l'RESSES
of 2,000 oF would require Ra = 7,000 psi. At extremely low upsetting

speeds of approx. 1.2 in. jmin . and large ingots weighing about 155 tons,
figures even as hw as 1,700 psi. havc been e::;tabli::;hed. As the dcfor-
1.WO 1.800
I I I I I I I i I I I
i!5 '.
psi
kpJm nf\ \ 30,000
lO , \ '\ 1',
1'\ \1', IU5%C
~ 20,000
'
15 \ ,
\ " azz ~
-~
10 "
/
aoi' / 10.000
5
~.
... ...;:
~
O
600 700 800 900 1.000 1,100 l,Zoo 0e O
Temperolure
Fig. 2. Specific TP-i',btancep, of uefonnatioll for earbun ~tpel~ H,t di1[el'cnt temperatllre. HiJ,!llf'st ,ll'grpi'
of ll})l-:ipUing :50CX); upp,etting Rlleed G(% p e]' :-i('cond (a('(·ording tu HF.N~;]<:C RB).
mation resistance, however, increase::; considerably with progressivc

cooling of the forgings, particularly small forgings , in most ca::;es a value
of Ba = 14,000 to 21,000 psi. is used for calculating the press load. When
piercing in a closed die, where the material has to risc opposite to the
ram movement, one has to reckon with a dcformation resistance of
28,000 to 42,000 psi.
By the inclusion of the friction resistance RI in stuffing boxes and
guide bushings and the own weight G of the mov ing masses, the nominal
press load is obtained: -
If G is effective in the operating direction as is thc case with ali

down-acting presses (push-down type presses), thcn Pn = P.
b) Ingots and Forging Dies

Table 1 shows dimensions of ingots which are ~worked undeI' a
forging press with dies according to fig. 3.
A top and a bottom flat die are used for flatening out the work-
piece, a top flat die and a bottom V -die are used for round forging, ami
INGOTS AND FORGING DIES 5
both top and bottom V-dies for hollow forging (fig. 4). The die V-shape
corresponds to an angle of tX = 100 to lloa. The dies are made of cast
steel. The working surfaces are hardened and replaceable for large ingots.
Fig. 3. lflat alltl V-,liC8 (8ce table 2, p. 15).
Fig. 4. Manufucturc of a scamless high-]ll'cssure vesse! of aht. r.9 in. interna! dianwtcr, n.r. i11. wall
thickness, and 49 ft. lellgth. (~hoJl pilota: KruPJl, Essen.)
The bearing surfaces are made to a width-Iength ratio of usually w: l

= 1: 4 to 1: 3 and they are sized so as to keep the bearing pressure
P = w ~ l within 5,700 to 8,000 psi. The dies are centered in the operating
position and are secured by means of bolts, dowels 01' wedgcs with a
1: 100 taper.
Furthermore, depending on the various forging operations, suitablc
auxiliary and additional equipmcnt will bc rcquired (sec fig. 5).
For the forging of special alloyed steel which requircs higher bcaring
pressure than low-alloy steel or just carbon stecl, cooling of thc dic
6 PRINCIPLES OF FORGING PRESSES
surfaees is provided in order ta inerease toollife. For this purpose, the

exehangeable die surfaees are provided with straight bores for the passage
}'jg. 5. ]:'orgillg of a rhig on a G,{)On-toll l1TrS~:i.
of the eooling water; the bores are eonneeted ta plant watcr Ly mean8
of shielded hose or telescopic tubes.
c) Pressure Fluids
For a long time, ,vater had bccn utied exclusively for the opcratiOl'
of forging presses. \Vith the dcvelopment of efficient oiI pUmptL altio
the oil-hydraulic operation has becn applied in forgc shopo,L As the charac-
teristics of water and oiI are batiicly different, they consideraLly affeei
those construction parts with which they are in contact.
The eompressability of the hydraulie fluid entails that the full operat-
ing pressure in the main cylinder wiU be reaehed only aHer a certain
period of time from opening thc inlet valve. This iti very disturbing,
particularly for high-speed forging presses operating with agreat
number of strokes per minute. The medium eompressaLility of waier i"
45.10- 6 , of oiI, depending an the kind of oiI, 60 ta 70.10- 6 units o{
volume for eaeh 1 atm. pressure inerease. Ineluding expansion of vessels
and piping, an inereasc of volume Ly 0.33% per 1,000 psi. must Lc
PRESSURE FLUIDS 7
taken into account for water and about 0.5% per 1,000 psi. for oiI.
On the other hand, this additional volume has to be drained before
the beginning of the return movement in order to decompress the
cylinders.
The characteristic of water to create corrosion in conjunction with
air can be kept within bearable limits by adding 1 to 2% emulsifiable oiI
that wiIl apply a protecting oiI film to the contacting surfaces and also
establish a certain lubrication effect on the moving surfaces. Before
emulsification the water is softened up to a pH-value of about 8. Duc
to the unavoidable mud-like and foamy segregations which take place
in the course of time, a renewal of the press water becomes necessary
from time to time; this is usually done once a year.
The pistons are sealed by means of clearanceless packings of vulcanized
plastics with plies of fabric. These packings create a relatively high
friction and, therefore, especially smooth bearing surfaccs and careful
lubrication are necessary.
In case of oiI operation, the pressure fluid serves at the same time
as corrosion protection and lubricant. Acidless, chemically stable mineral
oils with a medium viscosity of 4.5 °E at 122 oF are recommended for
the opera tion of hydra ulic presses. The hydraulic oiI has to be renewed from
time to time due to the fact that the oiI ages because of heat and una-
voidable contact with air. Press installations require such an oii renewal
about every 5,000 to 6,000 operating hours. Due to the relatively high
viscosity of the oiI, larger diameters for piping and control gears have
to be chosen than for water operation in order to avoid increase of
pressure losses due to flow resistances.
The sealing of the oiI pistons may be handled similar to sealing of
the water pistons, the gre ater viscosity of the oil and its lubricity permit,
however, application of the self-tightening cast-iron piston rings which
cause only minute friction losses and have a practically unlimited life.
On pistons below 3 in. in diameter, sealing can be achieved by grinding,
without using piston rings, if the diameter clearance is such as to ensure
good piston guidance, and if the by-passing amount of oil is sufficient
to constantly renew the oiI film and to cool the sealing area. This permits
application of slide valves for the controls instead of puppet valves,
while water operation requires the use of puppet valves.
The oiI stream which takes care of scavenging and lubrication of the
moving parts, has to be collected at each sealing point and again fed
through filters into the reservoir. This required oiI stream is of ten
erroneously called "Ieak oil". Leak oiI that reaches the open air uninten-
tionally must be carefully avoided because of fire hazard, apart from
contamination of machine parts and shop floor as well as destruction
of the concrete foundation.
8 PRIXCIPLES OF FORGING l'HESSES
The point of ignition of most hydraulic oils lies at about 390 0 t.o
480 oF. AIso, non-flammable hydraulic oils have been developed which
are occasionally used. The considerably higher cost of these oils, however,
does not yet permit general application.
The much cheaper operating medium watcr is stiH given preference
because of easy maintenance despite the progressing development of the
oiI drive. Leak water, moreover, does not cause similar fire hazards as
oiI would, and may be avoidcd at mov ing sealing points simply by
ţightening the packing.
For accumulators water operation is also more advantageous due to
the fact that compressed air may be used, whereas oiI accumulators
require nitrogen as pressure medium; the use of air could possibly form
an explosive oil-air mixture.
At the contacting surface the air or the nitrogen is being absorbed
by the hydraulic fluid. Each amount of pressure conforms to a certain
degree of saturation which may be reached after a certain contacting
period. At full saturation under hydraulic pressure of 3,000 psi., approxi-
mately 1.5 to 2% by volumc air in water and about 7 to 8% by volume
nitrogen in oiI are dissolved ~which segregate very quickly in form of
bubbles during pressure drop. This may cause \vear in passagcs which
are too narrow with regard to free flow, and at pressure regulating points
due to cavitation. Furthermore, the compressability of thc fluid is in-
crea sed considerably by bubbles which are carricd along.
d) Kinds of Drive
The hydraulic fiuid that is required for the operation of hydraulic
presses is generated mainly by high-pressure pumps which are nowa-
days almost exclusively driven by electric motors. In former times, when
steam was the only operating medium, either high-pressure water pumps
drivcn by steam engines were used 01' pressurc intcnsifien;, so-callcu
piston intensifiers, which are stiH in operation in those plants whcre
steam is being used extensively OI' in far-ofi' territorie" wit.h self-suffi-
ciency. In a similar way, compressed aiI' is used chiefly a" hot air, where
available with little cost because of waste-heat utili>':ation. Pressure inten-
sifiers are nowadays usually layed out for mechanical operation.
While pumps can deliver any continuou" amount of fluid, inten-
sifiers cause an oscillating mohon of a limited amount of fluid. This al-
ready shows two basic differences of press operation. Moreover, the fluid
delivered by pumps may either be fed directIy into the pre8s cylinder
01' into an accumulator from which it is taken as occasion demands.
Fig. 6 shmvs schematically deliYery diagrams of the various kinds of
drive and indicates the possible method of operation of thc pres::; con-
KINDS OF DRIVE 9
nected . Therefore, the decision for one or the other kind of operation
depends first of all on the required working conditions of the press;
but also on the purchas-
ing price and the running
energy consumption of
the drive.
If the forging press is
directly connected to the t Oirecf plJmp dfYVe
pump (fig. 6a), the ram
speed results from the a
delivered hydraulic fluid
per unit time. Therefore,
the delivery has to be
calculated for the highest
operating speed of the
press ; if this occurs only Oirecf driyc
for a short period of time b """"'u.a.,.-.-- IoJ.,U.J....~__ by sleam-or
with relation to the work- flir in/ensifier
ing cycle or scarcely in
a certain working pro-
gram, then a large pro-
portion of the installed
pump capacity will not be
utilized . Therefore, the
initial cost for the pumps
is relatively high. On the
other hand, however, the c
Oirecl drive
capacity delivered by the ay cron/r gear
pumps wiIl at any time inlensifier
correspond to the actual
press requirements, be-
cause the generated hy-
draulic pressure corre-
sponds to any forging re-
sistance. Therefore , the
direct pump drive is partic- Indirecl
ularly economical with acclJmlJ/olor dri/l~
regard to the running

energy consumption. In
order to keep the usually
very fluctuating capacity Fig . fi a-do Kinus o f urivc for forging presses.
away from the electric ITllIID DeIivery of pressurc fluid; I I Pressure]css cirClIlat ioll
motor and power supply or re tllrll.
respectively, a fly-wheel may be incorporated, preferably on the fast-

running shaft, the moment of gyration of which must be big enough to
hold the short-time peak pressure and to keep the drop of rotation
speed within a permissible amount. The normal motor rating will,
therefore, be considerably lower than the peak capacity of the pump.
Piston intensifiers supply - also directly - with one stroke the
required fluid for one press stroke which is called "single stroke", and
then re turn again to their starting position. The ratio of intensifier
stroke and generated press strokc is reciprocal to the corresponding
ram areas. The intensifier stroke is designed for the largest forging
stroke. Sometimes, however, larger strokes become desirable, e. g. for
piercing and cutting; and by means of controls it is possible to achieve
several single strokes without intermediate returns (progressive single
strokes).
Piston intensifiers (fig. 6b) are operated with steam OI' aiI' of 115 to
170 psi. and are designed to produce a maximum hydraulic pressure of
about 5,700 to 7,000 psi. Operating speed and generated hydraulic
pressure may be regulated within certain limits by throttling steam or
aiI' supply. As these piston intensifiers are always working with fuIl
pressure, that is without expansion, and are therefore operating with
uneconomieal utilization of energy, the applieation of this kind of drive
is justified only where steam OI' aiI' are generated cheaply and where
,vaste steam OI' waste aiI' are being re-used.
If the drive of the intensifier is effected mechanically by means of
motor, gear and crank (fig. 6c), the prcss wiU be operating in rhythm
with the crank gear with constant oscillating stroke, and very large
number of strokes per minute may be attained. On the other hand it il'
also possible to execute single strokes by incorporating a mechanical or
hydraulical clutch. A rack or spinelle elrive can be provided instead of
the crank gear drive.
The directly driving pump 01' the pressure intensifier cannot readily
be used for other hydraulical movements at the same time, as the deli-
vered pressure fluid would follow the way of the lowest resistance. It
would be better, in this case, to install a separate accumulator and il
little pump for the auxiliary movcments and the press return.
Forging presses which are connected to the pumps indirectly through
accumulator (fig. 6d), can be layed out for any number of strokes and
for unlimited operating speeds with only the velocity of flow in control
gears and piping setting the upper limit. The ac cumula tor also permits
simultaneous operation of auxiliary hydraulic movements and central
feed of several presses. As the hydraulic fluid is delivered at about
constant pressure, an adaptation to the forging resistancc anel a decrease
of the operating speed could be simply done only by throttling the
TYPES OF CONSTRUCTION Il
fluid to the main cylinder, thus wasting a considerable amount of accumu-

lated energy.
Three-cylinder presses with several pressure stages can eliminate
this disadvantage only partiaIly. It should be mentioned, however,
that also the direct drive with electrically driven pumps or intensifiers
causes an insufficient utilization of energy, if - like in most cases -
much idle time is obtained and very seldom the full hydraulic pressure
is utilized. In this case, the electrical efficiency of the direct drive be-
comes extremely bad.
On the other hand, the delivery of the feed pumps for accumulators
may be considerably reduced with regard to the operating speed of the
forging ram, because they have to meet only the average requirements
of a complete working cycle as compared with direct drive with pumps
or intensifiers. Moreover, feed pumps do not overload the power supply
and make use of fly-wheels superfluous on account of the almost constant
hydraulic pressure.
Presses equipped with accumulators are, therefore, suitable for diverse
forging programs and are chiefly used for especiaIly large press loads.
The most suitable drive for a proposed forging press installation
may be determined only by knowledge of the intended forging operations,
frequency of the various programs, the required operating speeds and
the simultaneous auxiliary movements; furthermore, purchasing and
operating costs as well as required space have to be taken into account.
e) Types of Construction
In order to contain the stresses within the press, the press load
a pplied on to the forging is taken up by either a frame consisting of
upper and lower platens and their connecting columns or a moment-
resisting single frame stand and finaIly returned to the cylinder support.
Thus we differentiate between column presses and open-jaw presses.
The four-column press as the oldest type of construction meets aU
essential shop requirements for a hydraulic press, namely accessibility
of the workpiece in both longitudinal and lateral directions (see fig. 7),
the use of table and die slide arrangements, the possibility of employing
pressure stages, stability against excentric press loads etc.
The two-column press ofl"ers increased overall accessibility by off-set
column positions, but requires, however, an increased column distance
for the same daylight and thus increased platen weights. Stability
against excentric loads is different in both principle planes (see also
chapter "Columns and Nuts").
Conventional column presses with top cylinder, fixed columns, and
moving platen (fig. 7 a) impede in many cases holding and rotating of the
forging, as the crane chain cannot be brought close enough to the die due
to the width of the cylinder platen. Multiple-cylinder presses with two
OI' three press cylinders of decreased outside diameters offer more
advantageous conditions. Two-cylinder presses give space for central
b c
y/inrler crosshead
}'ig. 7a-('. TYVes of COllstrllctioll. a) Vush-do\YIl de:-:.ign; 11) PlIll-doWll <h'sigu; c) Sillgk-frallJe dp:-;Îgn.
guiding of the moving platen while three-cylinder presses render possiblc

splitting up of the press load into three stages.
A particularly narrow platen may be achieved by thc pull-down
design (fig. 7b); just the reversed appearance of the moving-crosshead
design. It features the low total height which may be decisivc in case of a
"hallow building or shallow crane travel, furthermore, the decreased frec
column length providing a decreased column deflection. The disadvan-
tages are the increased pit depth and the considerably larger tlhare of
moving masses which transmit dynamical forces to the foundation at
high numbers of stroke. \Vith increased application of forging manipula-
tors, the small platcn width is losing its importance.
FORGING PRESSES 13
Forging presses with moving frame were designed as light metal die
forging presses up to the largest capacities (see p. 256 et seq.) and became
known as two-column presses up to press loads of approx. 2,200 tons.
Single-frame presses (fig. 7 c) feature extremely good accessibility
of the workpiece and are, therefore, used very extensively. Due to their
relatively expensive and costly frame design, however, they are built
only up to 1,300 tons capacity.
Chapter 1
FORGING PRESSES
a) Forging Presses of Moving-Crosshead Design
Forging presses with moving crosshead and top press cylinder are
mostly used (fig. 8). They have been built for press capacities up to
Fig, 8 .Stealll-hydraulic 16,500 ton~ forging pres~ of thrcc-cylillder de:-;ign to handle ingot::; of nI) hl
;l;l U tOl";. (~hujl pilot O ; KrujlJl, Ess('ll.)
14 FORGING PRESSES
16,500 tons and handle ingots of up to 300 tons (fig. 9). 1'his design i,;
the original type of forging pres,; construction and is, therefore, the basis
for aU subsequent developments of forging presses.
1'he press frame whieh ensures a self-contained flux of force, consists
of bottom platen and top platen, which are usually connected to each
other by four columns. 1'he press rests either on the lower column shoul-
ciers or on consoles integrally cast
with the base platen. 1'he top platon
contains either one or several pre8S
cylinders. 1'he plungers transmit thc
press force to the moving crosshead.
which is usually guided by the four
columns and which i8 provided for
carrying the upper tools. 1'he retum
device mounts either against the top
platen or the bottom or base platen
and is operated, depending on the
method of operation, by either steam.
compressed air, pressure water, or oil.
1'he base platen is provided with
a fixed holding plate or a movable
table for fastening the lower tools.
1'he movable table accelerates and
facilitates the change of dies and thc
handling of forgings. 1'he movable
table is particularly suita bie for thc
production of picrced billets in a
container l ). In this case, thc container
Fig. 9. 250-ton ingot for a 16,500-ton forging
pres". Width acros; comers approx. IUn in., is shifted out of the press by the tabk
ingot lcngth abt. 800 in. (Sho]l ]lhoto Kru]l]J,
E8sen.) and the billet is inserted and ejected
outside the press. lf both sides of
the platen are provided with an ejecting device, two eontainers may 1)('
u,;ed in order to increase production.
For designing a forging press, the following figures and main dimen-
sions must be known: - press capacity, main stroke, daylight between
mounting plates for upper and lower tools, the table dimensions, and
clearance between columns or distances betwcen eolumn centcrs (sec
fig. 7). 1'he dimensions depend on the forging work to be done. 1'he
length-width ratio of the columns' distance is mostly
a:b= 1:0.5to 1:0.7.
1) MULLER, E.: Hydraulische Pressen und Druckfiiissigkcitsanlagen, Bd. 2.
Pressen fiir die Herstellung und V crarbeitung von Rohren, Hohlkiirpern, Platkn
und Blechen aus Stahl, I3crlinjCiiittingcn/Heidelbcrg: i::îpringer 19;';5.
FORGING PRESSES OF MOVING·CROSSHEAD DESIGN 15
The daylight dimension c is composed of

c = h1 + h2 +h- 2 in. (see fig. 3)
where
h 1 and h2 = height of the dies,
h - 2 in. = ram stroke, decreased by a dimension for subsequent
re.finishing of the dies.
Proven main dimensions for forging presses are listed in table No. 2.
Table 2. Main Dirnensions of Forging Presses of Four·Colurnn Design 1 )
IJrcss Column s F orging di cs

cHpaci t y 'tJ'o h: c Da~· ·
light
-- -
eenter di stnnces UaLio Die are:\ Hatio I! cn ,ing
a I'r s lIr c
p .0
II c (t and li . u· 1 x "~l
I
J'
wx l
lons iu. in. in. iI''1. Il i.
550 32 70 55 35 1 : 0 .64 28 x 7 1:4 5,700

700 32 70 1
(i3 35 1:0.56 32 x 8 1:4 6,100
880 35 80 70 40 . 1:0.57 33 x 9 1:3.7 6,300
1,100 40 88 80 50 1:0.63 40x lO 1:4 5,800
1,370 50 100 80 50 1:0.63 « x ll 1:4 5,800
1,760 55 110 100 55 1:0.55 50x 12 1 :4.2 5,900
2,200 63 124 110 63 1:0.57 55 x l4 1 :3.9 5,900
2,750 63 124 110 70 1:0.64 55 x 16 1 :3.4 6,400
3,500 70 140 125 80 1:0.64 63x 18 1:3.5 6,300
4,400 80 160 140 88 1:0.63 70x 20 1:3.5 6,400
5,500 93 175 200 100 1:0.5 80 x 24 1 :3.3 6,000
7,000 105 210 200 105 1:0.52 100 x 24 1:4.2 6,000
8,800 IlO 240 215 110 1 :0.51 105x 28 1 :3.8 6,200
11 ,000 120 250 240 125 1:0.52 IlO x 32 1 :3.5 6,400
14,000 120 270 250 130 1:0.52 125x 35 1 :3.6 6,300
17,600 125 280 270 140 1:0.52 140x 40 1 :3.5 6,500
1. Bottom or Base Platens

The base platen is made of cast steel (ASTM A·27 GR. 60·30 or
ASTM A·148 GR. 80·40) and is calculated for fatigue strength as a beam
supported at both ends under the assumption of symmetrically applied
loads. The distance of support equals the distance a of the column
centers (see fig. 7). The possibility of an off·center ar even tilted position
of the workpiece on the lower die has to be taken into account and, therc·
fore, additional loads accrue which cannot easily be determined. These
Joads are usually taken into consideration bycalculatingwith a permissible
nominal bending stress of 6,400 to 8,500 psi. under the retention of the
afore·mentioned load assumption. It is advisable to make the platen
together with the integrally cast lugs for the columns as a rugged box·
type construction to resist the bending moments and the shearing loads.
The required cored holes for casting must be carefully designed and
1) As rcgards table dimcnsions sec table 3, p. 22.

16 FORGING PRESSES
taken into account for ca1cu1ating the p1aten. Improper position and
shape of the cored ho1es may tremendous1y reduce the strength of the
p1aten 1 ).
Even more critica1 than additiona1 mechanica1 stresses are casting
stresses which frequent1y result from change in thickness of section.
.
• •
"
') PFLEIDERER, C.: Der EinfluB von Liichern oder Schlitzen in der neutralell
Schicht gebogener Balken auf ihre Tragfăhigkeit. Mitt. iiber Forschungsarbeiten,
Berlin: Springer 1911.
FORGING PRESSES OF MOVING-CROSSHEAD DESIGN 17
When designing base platens, a favorable blending of the different

cross-sections must be considered; proper heat treatment after casting
is to improve the grain structure and eliminate casting stresses. In order
to obtain a good design it is recommendable to closely co-operate with
the steel foundry during the design stage.
For press capacities up to abt. 4,400 tons, the base platens of forging
presses may be one single piece without exceeding the permissible weight
and the overall dimensions for transportation. For larger press capacities,
however, the base platen has to be a multiple-part design (figs. 10 and Il).
r:t--
i
"
Seclion C-[) Platen C/WJ - SCc!iOfi A -lJ

~Fig. 11. Multiple-pieee base platen of an 1l,OOO-ton forging press with shifting table aud wedg.-
adjustmeut at the column ends for aligning the plat eu at assembly. (By: Kreuscr, HaIlllll.)
The platen should be split only at those sections where the bending
moment to be transmitted is as small as possible. The bending moment
must be taken by shrink bolts or shrink rings. The bolts have to be
designed as necked-down bolts.
The height H of the cast lugs usually equals the height of the base
platen, it is, however, kept within the favorable limits developed by
experience of H = 2.5 to 3.5 d; d being the column mameter.
In order te ensure a positive support on the foundation, the base
platen may be provided with extension beams cast to the column lugs
(figs. 12 and 13), in case of particularly large distance between column
centers, however, the press may also be supported by column feet
(figs. 10 and Il).
2 ~Iiiller, Hyclraulic ]<'orging l're"rs
J'i;!. li. 2,2UU-Lun furgill~ "J'(';~ uf O Il C- ......
1')·linucr design lI'ilh ~ hirli ng table "hm- 00
able to c ilhor "ide. ], jecting dc vicc i ll
ccnter o f !)ase platen, balanei "g cylilldcrs
ro r the \\,cight of tllC lIIovillg crog,;hcnd
il "d prc<su ra \Vatc r fecd t hrough tJoc
hollow coltllH n ~ .
CUy: ::ithIO(' ''''"l1l , Dii""cl,lorf".)
6
;o
o....
7:
O
>Tj
;o
t>:
[fJ
[fJ
t'j
[fJ
FORGING PRESSES OF lVlOVING-CROSSHEAD DESIGN 19
The shifting table is made of cast steel (ASTM A-27 GR. 60-30); cast
iron (ASTM A- 48 class 30) may also be used for the shifting table for
small capacity presses up to approx. 1,650 tons. The guide ways at the
base platen are provided with cast iron wear plates for a cast steel
table. The guide has to be designed in such a way as to prevent any
}'ig. 1:;. ShO]J usscmbly of forging ]Jreso shown an fig. 12.
contamination of the sliding surfaces by scale and other foreign matter.

In order to protect the guide ways from scale, they are provided with
cover plates which are hooked-in at the table ends and wiIl move along
with the table. The length of the shifting table depends on the kind
of operation to be done. For installing the forging die, a short table would
be sufficient; for opening-out operations or ring forging over mandrel
(fig. 47), however, a long table would be required. The table width is
limited by location of the columns.
For determining the shifting stroke, investigations have to be made
how close to the press the tools can be brought by the crane. Furthermore,
it must be decided whether the table is to be extendable out of the prcss
to either one or two dircctions.
2*
20 FORGING PRESSES
In few cases the shifting table consists of three die plates (fig. 52,
p. 60) connected to each other; jf disconnected, they may be moved
separately and be pulled out of press center relatively far, ensuring that
several dies are always available for die change. The disadvantage of the
Fig. 1-1-. Basc platcn ofa Hi,500-tOll fOl'ging pres:; with ~ hiftillg tahle and ]atf'ral clip ~lide a rra IIW'1ll 1 nt.
(By: Schloemanll. Diissl'ldorf.)
multiple-piece shifting table, however, is the exposurc of the guide ways

between the single plates.
The tool is fastened to the shifting table by wedges , bolts OI' studs
for which proper slots and tapered holes must be provided; a centcring
stud may serve for centering.
In order to prevent dislocation of the table during forging operation,
the base platen must be equipped w'ith an interlocking device. This is a
locking bar located alongside the table, usually in center of press , and is
operated either mechanically in connection with a tipping lever OI'. on
large presses , hydraulically. Frequently, cogging is provided alongside

the table for interlocking it in different positions.
An electric or hydraulic drive is used for moving the shifting table.
In case of the electric table drive, a reversing motor works through
a gear and a slipper clutch on a pinion with rack, worm drive is not
!1'ig. 15 . Basc platen of a 6 ,6 0J-ton fOl'ging press with shifting table anlliatcral die sUd e arrangenll'llt.
(By: HydrflUlik, })uioburg.)
suitable because of contamination. The electric table drive is only used

to a little extent as it is suitable only for those presses which are operated
by steam or air. Gas operating media have to be excluded for shifting
the table due to their ability to expand causing an uneven table move-
ment and due to the required big eylinder dimension because of available
pressure of usually not over 140 to 170 psi.
The considerably simpler hydraulic table drive may also be employed
on steam- or air-hydraulic forging presses , if a hydraulic pump is
providerl for the direct drive of the shifting cylinders. An additional
22 FORGI:KG PHESSES
advantage of this arrangement is the precisc speed control as compare(l

with electric table drive with three-phase A. C. current.
There are two different designs of the hydraulic tablc drive, namely
the direct shifting and the shifting by steps. The first design, where the
shifting plungers are rigidly connected to the table, is suitable for short
strokes and one-sided shifting up to aht. 6 to 10 feet . For larger strokes,
the second design would be advantageous (figs. 12 to 15); in this case,
shifting is done step by step, the table being repeatedly coupled by ro(l
to a shifting hand which can be moved back and forth underneath the
table and which is provided with several rod holes within one plunger
stroke. The total shifting stroke , therefore, depends only upon the table
length and not upon the plunger stroke. Since the application of forc('
usually does not take place at center line of ram, provisions must hp
made for good guiding of the plunger head. Fig. 11 shows a shifting
device designed according to this principle , where the shifting band
has been replaced by a movable cylinder. The cylinder is provided with
several notches for the consecutive insertion of the locking bar.
The shifting power is calculated by the equationfi's = .u .N. Thc
nominal load N is composed of the weights of the shifting tablc, the
largest ingot and the tools. The coefficient of frietion of .u = 0.5 to 0.6
has been derived from experienee. The aeeeleration foree may be neg-
eeted. Proven dimensions of shifting tables are given in table No. 3.
Table 3. Main ])imensions of Onc-Piece Shifting 'l'ablcs al/(l Jar Ejecting Devia"
for Fow'-Column Forginq Presses
Shift ing Table Ejcctor
Prc_s Tablc arca

--
Table shifting
I strokc
)lnl11
I
:lIant
~ rcc for ce
I
Ejccting Sharc of
tllo press
-
Ljcctor
fain
clI pacity both capaCity strokc
oll csidc I , ido.
ton in. m. in. in. ton t on % jn~
I
550 70 x 35 40 40 11 35 6.3 24
700 70x 35 40 40 11 39 5.6 24
880 Ox 44 44 44 17.6 44 5 28
1,100 80x 44 44 44 17.6 55 5 30
1,380 88 x 50 50 50 22 70 5 32
1,760 88 x 60 50 50 24 8 J<
35
2,200 llOx 63 60 60 35 110 5 40
2750 146 x 67 70 70 44 140 5 44
2,750 240x 67 160 80 88 140 5 44

3,500 240 x 80 180 110 165 4. 50
4,400 240 x 88 180 8 140 220 5 52
5,.500 240x 110 180 8 165 220 4 52
7,000 320x 125 240 120 200 250 3.55 52
8,800 320x 140 240 120 220 275 3.15 60
ll ,OOO 400 x 160 280 140 275 275 2.5 60
14,000 400 x 160 280 140 310 330 2.4 60
17,600 400 x 160 2 O 140 330 410 2.35 60
FORGING PR ESSES OF MOVING-CROSSHEAD DESIG N 23
In order to allow for a quick change of forging dies when switching
from a round to an angular forging cross-section, the press is sometimes
Fig. 16. Cross-section through late ral dic s!ide arrangemcnt at the base platen shown on lig. H.
}' ig. 17. 2,750-ton forgillg prcss with shifting table and lateral die s!ide arrangement. (By: Hydran!ik
Duisburg.)
equipped with a lateral die slide arrangement (figs. 16 and 17) . It consists
of a narrow frame with two small hydraulic cylinders. The plungers move
24 FORGING PRESSES
a shifting tie, similarly to the tie that moves the shifting table, thus
pulling the two clies which are connected to each other, through the
press step by step.
The cylinder force of the lateral die slide arrangement is made
equal to the weights to be moved; the stroke is designed in such a way
that not more than two strokes wiIl be required for moving the dies
out of the press.
An ejecting device at the base platen which is used for ejecting the
forged piece when closed-die forging or piercing, may be located either
at center or at front or re ar of press respectively, where the distancc
to press center is made equal to one stroke of the shifting device (fig. 18).
}·'ig. 18. Ejecting device and drivc of the sltifting tic. (By: Hy,lraulik, Duislmrg.)
It is practical to arrange the ejecting device in such a way that the

cylinder travels over a fixed ram , thus protecting the packing and slid-
ing surface from contamination. The ejecting rod is frequently screwed
into the cylinder bottom and guided in the top part of the base platen.
The shifting table and shifting tie must be provided with an opening
for clearing the ejecting rod. The ejecting cylinder is retracted and moved
downwards by two small side cylinders acting on a cross tie rod.
In order to eliminate the return cylinders, the fixed ram may be
arranged for double action; this design, however, is less frequently used
due to the complicated replacement of packings. For ejecting devices
with a capacity of up to 100 tons, it would be more advantageous to
replace the hydraulic return by a weight.
As piercing operations are most frequently being done on actual
piercing presses and drop forgings are produced by hammers, forging
presses are usually not equipped with an ejecting device; it is recommend-
ed, however, to provide for the possibility to later on install an ejecting
device, thus increasing the range of press operation without any un-
favorable modifications to the original press construction. Proven dimen-

sions for ejecting devices are shown on table No. 3.
2. Cylinder Platens
The same principles for the basic design and for calculation that
apply to the base platens, hold also true for the cylinder platens, if the
latter serve only for the insertion of a cylinder and do not form a one-
piece unit with the cylinder. The material used is cast steel (ASTM A-27
Grade 60-30 or ASTM A-148 Grade 80-40). The permissible nominal
bending stresses are not to exceed 7,000 to 10,000 psi. Aiso here, the
Fig. 19. Multiple-pieee cylinder platen fur a 16,500-ton threc-cylindel' forging press.
(By: Hydraulik Dui"burg.)
height of the column lugs is made equal to the platen height, with the
height limit, set by experience, of H = 2.5 to 3.5 d. On larger type
presses, several cylinders are usually inserted into the platen (fig. 19);
they should have some clearance in the bored openings; this clearance
can be determined with sufficient closeness by calculating the expansion
of the cylinder under stresses. The split surface of composite cylinder
platens are parallel to the lateral press axis. The platen width is made as
small as possible, so that the crane chain can be brought close to the
press in order to handle short forgings and ingots and work as close to
the die as possible. The front surfaces of the platen are sometimes provided
with guards to prevent the crane cab les and pulleys from being caught
by extending parts. The narrow sides are provided with integrally cast
lugs or machined surfaces for mounting the return cylinders. Furthermore,
the column lugs will have some machined surfaces for mounting hand-
ling devices and hydraulic pulleys for lifting the forging tools.
When reconditioning a forging press after years of operation, somc-
times the unpleasant discovery is made that the cylinder seats in the top
26 FORGING PRESSES
platen are distorted by several sixteenth of an inch. Frequently thcsc

distortions only occur in a certain area which, in most cases, is traced
back to unilateral use of a forging press. In order to avoid in these cases
the costly replacement of cylinders, the cylinder platen has been opencd
out, with good success and little expence, and liners with 3/4" wall
thickness have been inserted into the openings by means of deep frcezing
technique 1). The cooling-down of the liner is effected by liquid carbon
dioxide in a bath of methyl alcohol down to a temperature of abt.
-95 oF.
3. Columus aud Nuts

The columns effect the seIf-contained connection between top and
base platens and are usually also used for guiding the moving platon.
In case of a symmetrical forging resistance, the columns arc only tensioll-
stressed if the platens are considered rigid bodies and if assumed that the
load is evenly distributed to aH columns. Therefore, the nominal tension
stress would be
p
8/1 = nA,.
where
8" = nominal stress in psi.,
l' = max. press load in lbs.,
n = number of columns,
A, = smallest column cross-sectional area in sq. in.
If, however, an eccentric forging resistance occurs according to

figs.20a and 20b, as is frequentJy the case during forging operatioll,
a b c d
Fig. 20a-d. Effect of pre~s load at variolls forgillg opcrations and ul111:;;ual ]oeatiol1 ofthe ]\ot worli:.
an additional bending stress is applied to the columns which, in man)"

cases, is a multiple of the tension stresses. An additional bcnding strC8O'
may also arise by a horizontal component of the press load. This results
by friction at the die ways, if, for instance, the workpiece climbs up thc
1) J. Iron Steel Inst. 161 (1949) Febr. Issue.

FORGING PRESSES OF YlOVING-CROSSHEAD DESIGN 2i
V-die a little when being rotated by a crane chain (fig. 20c) or in case of
staggered pressure areas (fig. 20d). As the ingot finds its central position
with increasing operating force, only a fraction of the available press
load becomes effective in these cases.
Furthermore, the radiation heat of the hot work and the heat ex J
pansion of the moving crosshead may cause additional stresses in
the columns. Especially
when upsetting and
piercing an ingot, for
instance, the inner sur-
faces of the columns
are uninterruptedly ex-
posed to the heat radia-
tion which causes a
temperature in crease at
these surfaces resulting
in bending stresses in
the columns. A screen
Fig. 21. COllllllrnciug of llpsctting a,n ingot with a (1,GOO-ton l'ig. 22. Effect of an ecccntrie
furging prf'Ss. forging rasista.nce on the press
coluIllns.
of chains suspended from the moving crosshead protect the columns

from this heat radiation (see fig. 21) while the elongation of the moving
crosshead is compensated for by suitable design of the moving crosshead
guide.
For determining the bending stresses in the columns, an eccentrically
acting forging resistance at fuIl press load is usually taken into account;
the eccentricity is figured with 10% of total ram stroke.
28 FORGING PRESSES
The following calculation example for a four-column press is to only

consider the part which comprises a plain two-column system, e. g. the
part which is loaded with half the total press capacity P 2 :P = 0.5 P 2'
The basic effect of an eccentric forging resistance on this two-
column system (consisting of rigid platens and flexible columns) of a
four-column press is shown in fig. 22. The moment of eccentric load
trying to rotate the moving crosshead creates side forces acting on the
r Ip I j ) A A
li
,
19 ..:; E
"-
A
~
~
\
~
ţ
~ ~
~
\
P 17 111 ~ Bas/le
-- ~I ~
l1e /'ft+f1c /ines
~ 1
I I \ ~ r
a b c d
I I A A ~ io
, ;
1
...s
"
....,"
f
l- le J 1 J \ "'<; "'<;
J F'>.. i">-.
ili f ~
-
~
, J 1 ~ ~ -
1. I \ ~ r fi
Fig.2:3a- d. l:lcnding stress of columns through eccelltric forging resista llce allll nxed lJOl<lillg in tII('
platens, Sllear diagram.
columns and causes a translatory motion of the top platen against the
base platen.
The common constructions of the moving crosshead guides, designed
to compensate heat expansion, permit distribution of loads on the
columns as per shear diagram fig. 23. The side forces FI create bending
moments MI in the columns that are shown in fig. 23a for different.
elevated locations of the moving crosshead; fig. 23b shows the moments
M 2 resulting from translatory motion of the top platen. Fig. 23c shows
the combined moments MI and M 2 , which cause a deformation of tlH'
columns as per the elastic lines indicated in fig. 23 d .
The compilation of bending moments as per fig. 23c indicates that
the bending stress at the top column connection is greater than that at
the bottom column connection, which holds true within the mnge of the
common distances from moving crosshead to top and base platens. From
the fact that column cracks occur predominantly at the bottom connec-
tion, it may be gathered that the assumed fixed holding of columns does
not always hold true. At slackened top holding of the columns, which are
located in the platen lugs with clearance for reasons of erection and
construction, the moments from the translatory movement of the top
platen are only taken by the bottom column connections. This loading
----- !1omer7/.r ilS pe!' fig.Z3c fo!' compllf'ison
Fig. 24. Hcnding Htress of columns through eccentric forging resistance and slaekened holdillg' in top
lliaten.
case is shown in fig. 24 in the same scale as per fig. 23 according to which
the columns bend like a cantilever beam in case of translatory movement
of the top platen.
The comparison of the greatly varying results indicates that by
suitable design of the platen connections the stress conditions may be
improved, however, the considerable effects of maintenance, heat, and
wear in the guides cannot be determined. Therefore, the assumptions
can only be a rough estimate of the real stresses. From the column
cracks, which sometimes occur, it may be concluded, therefore, that
the greatest stresses in the columns occur at the connecting points to
the platens.
In order to obtain a simple calculation basis which corresponds to the
experience with proven designs, an exact determination of loads and
extensive calculations are omitted and the most unfavorable loading
case as per fig. 24 is assumed for stress calculation, according to which
the elevated location of the moving crosshead may be neglected and the
greatest bending moment occurs in the lower column parts. The moment
M = p. c caused by the eccentric forging resistance results in the clamp-
ing moments at the base platen
30 FORGING PRESSES
Together with the column tension force P t = ~- , a corn bincd nominal

stress arises:
and for the four-column press with P 2 = 2 P:
whcre
S= section modulus of culumn at the point considered (in. 3 ),
Ac = cross-sectional area of column (in. 2),
P2 = press load (lbs.),
c= eccentricity of forging resistance (in.).
The assumcd 10ading condition represents the unfavorable limit for

a four-column press, as well as the wide side of a two-column press.
However, this loading condition is fully effective in the narraw si de of
a two-column press, since the top platen cannot be forced to do trans-
latory motion in that direction (see fig. 25). This condition, with th0
instability of a two-column press aggravated by top cylinders and othel'
Fig. 25. Ntfcct of an cceclltric fOl'gillg T('~i:-;t<lllre 1·'ig.26. J.oad llhtrilmtio!l at l'fTt'lltric forging
on thc narrow sidc of fi two-eolwllll prl':'-:-i. r('si~tan('e a 11\1 COlll hin('cl ('o]mnn a Ild ::;talk
gniding of tJle l1HJvill,!.! cro:-;~hcad.
reasons, led to the preferrcd construction of the moving-frame typc

two-column pull-down press with thc press cylinders located at thc
bottom.
On starting the first 1ayout, frequently the ru1e of thumb for detcr-
mining the column diameters is used that the nominal ten sion stresses in
FORGING PRESSES OF l\WVING-CROSSHEAD DESIGN 31
case of the largest, centrally acting forging resistance is to be s ~ 7,OOOpsi.
This relatively low value ensures sufficient safety to take up the bencling
stresses, and the column diameters thus determined usuaIly correspond
to well-proven designs. Table No. 4 indicates column data of built four-
column presses, gathered from experience.
For forging presses with a central guide stem which is rigidly connect-
ed to the moving crosshead (see fig. 26), the afore-mentioned kind of
calculation gives the same column stresses, assuming the Same loads,
as with exclusive guiding of the moving platen at the columns as per
fig. 22 under the assumption that both columns share equaIly in the
load distribution. The lateral deflection of the top platen caused by
eccentric forging increases with the induced moment and may be used
with sufficient accuracy for inclicating the column stresses, assuming
normal operating elevations of the moving crosshead.
Table 4. Column Diameter for Forging Presses of the Four-Column Design
Pre 350440'55°170088011,1001,3801 ,76012200 2,7503,5004,400

olumn haft
<liam ter il1-
63 / 7 1 8 1 9 10 I 11 12 1/ 2 1 14 153/,. 1 1731.1 193/ 4 22
~Fig. 2i. Optical indicat ing devicc for measuring ·Fig.28. Electrical indicat.ing dcvice for lllea-
the lateral movelllent of the cylinder platen suring tlle lateral lllovement of tlte cylindcr
whcn forging cecentrically. a Conwlc; bLight platen when forging eccentrically. a Pivot;
source; c Marked pOint; d Twin binocular b Control rod; c Controllever; d ~Feeding deviet';
systCll1; e Ground glas:::; plate. e Control pjn; f Rcccivcr; g Buzzef.
32 FORGING PRESSES
The heavy presses in particular are therefore equipped with a column

deflection indicating device, so that the press operator does not have to
rely on his touch when reversing the machine in time. This device opera-
tes either electricaIly or opticaIly as per figs. 27 and 28. The electrical
indicating instruments may also easily be provided with safety measures
which become effective when the
permissible column deflection is
exceeded.
Only those columns, which arc
not used for guiding thc moving
crosshead, are free of bending
stresses. Such a loading case is
shown for a moving frame-type
press in fig. 29. The eccentrie
forging resistance creates only
unequal pulling forces in the two-
column system:
F t = ~ (J ± 2c
2 a
while the moment M = p. e 18
taken up by a central guide stern.
l10mMls in Ilie
I ·- c 1 fu/tie slo/Ir
This design has been executcd
only in few cases for forging
: --ml~ ! l1omenl.s in Ibe presses with top working cylindcr.
~ /owt/' pInten It has been abandoned later on
- -a.
~Fig. 29. Pull-down pres> with central gUide "!.alk.
due to a relatively large total
height and great expenses.
The force-transmitting construction parts of the forging press are
with each operating stroke subject to a revers al of stress, causing mainly
repetitive stresses. A daily 8-hour shift, for instancc, and an average
number of strokes of 500 per hour and 300 working days a ycar givcs
a load cycle of
n = 8·500·300-30 = 3.6.10 7
in 30 years.
Therefore, stress calculations must be based on fatigue life and the
influence of notches must be taken into account. If the columns are
provided with counter nuts at the point of support (see fig. 32), the
thread cross-sections are particularly endangered because of stress
concentration. Furthermore, a change of cross-sectional area, for instance
at shoulders, cause an increase of stress. For calculation, the actual
stresses slllax must be figured by determining the form factor :xl) at the
point of stress concentration, slIIax = CI. ·S".
1) Ree Hiitte 1, 28. Aufl ., p. 960.
As the load limit, i. e. the fatigue strength 8fmay be closely approached

in case of an elastic material and with the stress drop in question 1), a
relatively low safety factor SF will be required. The column diameter is
obtained by the relation
For columns usually a tough carbon steel (AISI 1035) is used, which
may be applied advantageously for construction parts under repetitive
stresses due to its lower stress-concentration index. In order to avoid
Fig. 30. Hollow-forged and borcd ealumns. I~en gtll 78 n., shaft diametcr 47 in. Wei ght of OIle pit·!'"
'tbt. 12" tuns. (TIy: S!'hloclllann, Diisscldarf.)
material defects which may result from column forging and show as tiny
cracks in the column core, heavy columns are either bored out or hollow-
forged , so that the core may be carefully checked over the whole length.
Boring-out is only applied for 20 in. to 30 in. diameter columns with
a bore diameter of 8 in. to 12 in. Column diameters exceeding 30 in. are
hollow-forged with an internal diameter of abt. 14 in. to 28 in. and
subsequently cleanly turned (fig. 30).
The bored-out column is considerably more expensive than the
heavy solid column of equal diameter. There are different opinions on
the advantages of using hollow or solid columns. The solid column,
because of its better thermal conductivity, may develop considerable
thermal stresses while exposed to the radiant heat of forging. Tempe-
ratures of 570 oF, e. g., have been measured at the column surface of a
1) SIEBEL, K: Neue Wege der Festigkeitsrechnung. VDI-Z. 90 (1948) S.135ff.

3 Miiller, Hydfaulic Forging l'l'csses
34 FORGING PRESSES
1l,OOO-ton press. By using a chain curtain suspendecl from the guide

lugs of the moving crosshead, the temperature had been dccrcasccl to
Table 5. Dimensions of BUUTPSS ThTeads for Colwnns

(Extract from DIN-Proposa1278F).
AlI dimensions are metric)
Bolt Nut
Piteh
diameter
Lead
--- ---
Thre:\C1 l100t dlnrn etcr _~ rea of root Thre,"l 1100&
diam etcr c1,amel('r rlia mele r diamctcr
(~
JllIII
d,
nUH cm:l
d,
mm "
mn\
D
]nll\
D,
Illnl
200 190,8 285,92 196 8 200 192

212 202,8 323,02 208 8 212 204
224 214,8 362,38 220 8 224 216
236 226,8 404,00 232 8 236 228
250 240,8 455,41 246 8 250 242
265 253,5 504,71 260 10 265 255
280 268,5 566,21 275 10 280 270
300 288,.5 653,70 295 10 300 290
315 303,5 723,45 310 10 315 305
335 321,2 810,29 329 12 335 323
355 341,2 914,34 349 12 355 343
375 361,2 1024,67 369 12 375 363
400 381,6 1143,69 392 16 400 384
425 406,6 1298,45 417 16 425 409
450 431,6 1463,03 442 16 450 434
475 456,6 1637,43 467 16 475 459
500 481,6 1821,64 492 16 500 484
530 507 2018,86 520 20 530 510
560 537 2264,84 550 20 560 540
600 577 2614,82 590 20 600 580
630 607 2893,79 620 20 630 610
670 642,4 3241,16 658 24 670 646
710 683,4 3675,36 698 24 710 686
750 722,4 4098,69 738 24 750 726
800 763,2 4574,74 784 32 800 768
850 813,2 5193,79 834 32 850 818
900 863,2 5852,11 884 32 900 868
950 913,2 6549,70 934 32 950 918
1000 963,2 7286,57 984 32 1000 968
1060 1014 8075,43 1040 40 1060 1020
1120 1074 9059,38 1100 40 1120 1080
1180 1134 10099,88 1160 40 1180 1140
1250 1204 11385,26 1230 40 1250 1210
1) Reprints of specifications in this book by permission of the Deutsche Normen-

ausschuB. Only the lastest editions of the specifications in standard sheet size
A 4 are authoritative. They may be obtaincd from Beuth-Vertrieb GmbH,
Berlin 30 and Cologne.
abt. 212 oF. Trials to use the hollow columns for prefilling and pressure
water supply did not prove to be successful because, due to cooling,
each column would have to be used for this purpose and because of
press vibrations it would be difficult to keep the flange connections at
the column ends tight and to fight corrosion.
The cylindrical sliding surface of the columns is smooth machined or
ground. In order to provide for adjustability of the sliding surfaces at
the moving crosshead, columns with a square cross-section were made or
round columns were covered with a cast sleeve that was supported by
prismatic guide plates. Despite its advantages, this design has been built
only very few times.
There are different types of threads for the platen connections of the
columns (see fig. 32). The most commonIy used thread is the buttress
thread as per DIN 2781. AII dimen-
sions of this thread are derived from
its pitch; this pitch depends on the
thread diameters (fig. 31 and table 5).
In case of a screwed connection
where the nut is compression-
stressed and the bolt is tension-
stressed, the bolt wouId be elongated
and the nut upset, thus causing a
deformation of the originaIIy even Fig. 31. Buttress thread for coJunllls.
thread pitches of both parts. There-
fore, only the first threads extending into the nut are used for load
transmission and are , therefore, subject to very high stresses. In cast
the yield point should bc exceeded, however, the load distribution
would de crease due to utilizing the following threads.
Fig. 32a shows the column connection at the platens with split nuts
and counter nuts. This design gives a rigid connection with large bearing
surface if the coIumn ends are pre-stressed. The thread, however , causes
a considerable stress concentration at the points of the largest bending
moment. The column shows no considera bIe difference between shaft
and shoulder diameters which is advantageous particularly when erecting
the forging press; in this case, the base platen, the moving crosshead and
the top platen may be put on top of each other and the columns may then
be inserted into the lugs from above. Prior to this, press cylinder and ram
are installed so that the top platen can be lifţed and properly located
simply by pumping water into the cylinder.
In order to prevent rotation of the outer nuts, a plate is put across
the face of column and bolted to these parts after erection is completed.
The inside nuts are usuaIIy not locked because they can easily be ovserved
during operation. If, however, a loose nut is not tightened in time, it digs
3*
36 FOItGING PRESS ES
into the bearing surface of the platen in thc coursc of timc duc to the
shock-like force of each working stroke. It happencd in such a case an a
2,200-ton press that the nut dug into its bearing surface 3/8in. dcep
after several years of operation.
b
rr
U,..f-. I
I. '/
~
~
I
I
I I
I I
~ I
/
l
I
II
II
II
I II
III, 1
. I
1.
II,
~
~"'jg. :t2a- f. Uolumll rUHl platen conllccti o n ~ for forgillg pr('~.i.,;,e~.
For equal pre-tensioning of the column ends, the press is overloaded

by 10 to 20% befo1'e tightening the inside nuts, by accordingly increasing
the operating water pressure by a hand pump.
Fig. 32b shows a column where the loweI' counter nut has been 1'e-
placed by a column shoulde1', whieh has tI) be 1'elatively thick so that it
does not dig into the platen. Due to elimination of the inside nuts, pre-
tensioning of the 10we1' column end pa1'ts can no more be effec:ted by
inC:1'easing the ope1'ating pressure, except by heating up the column end
and subsequent tightening of the outer nuG. The column is p1'ovided with
a hole in its cente1' to acc:omodate the heate1' OI' a hot rod, in order to
achieve the required elongation of the column end part. On erection, the
platens must be lifted over the columns.
Fig. 32c shows a column connection with shoulders at the tap and
base platens. In this case, the distances between shoulders of alI columns
must be equal and accurately kept, otherwise no rigid connection is
possible. Furthermore, the column lugs of the moving crosshead are
provided with relatively thick-walIed two-piece split bushings, since thc
column shoulders must pass through the openings of the moving cross-
head. The advantage of this
design is the de crease of notch
stresses at the highest-stressed
column points.
The column connection as
per figs. 32d and 33 has been
provided with a two- piece
tapered bushing (instead of
the lower counter nut ar
column shoulder) for centering
purposcs, which is without
clearance. This connection
eliminates almost completely
thc notch effect at the lower
point of support. In this case,
the press rests with its column
end surfaces an the foundation
with so-called column feet
Fig. 33. Column mounting at ha,se platcn a.ud arrangc-
placed in between, instead of lIlent of return cylinder8. (By: HydrauJik, Duishurg.)
resting an the foundation with
the extended consoles of the base platen. On heavy presses, the column
feet are frequently provided with a central passage through which the
column may be lowered at erection. If the return cylinders of the press
are mounted an the tap platen, care must be taken ta provide for afirm
and rigid connection between columns and base platen, in order ta
prevent the base platen from lifting off the column nuts when, for
instance, retracting a piercing rod.
A column connection that also eliminates a notch effect due ta
threads ar shoulder at the tap platen, is shown in fig. 32e. The rigid
connection is achieved by long tie rods, which must take up the weight
of the tap platen, the acceleration forces and the pullback power, if
required. As the dynamic forces may, however, increase ta a considerable
amount, e.g. when decompressing the press cylinder after each working
stroke, very strong anchoring elements are required.
The column connection as per fig. 32f offers the advantage of maxi-
38 FOItGlNG PRESSES
mum safety against the noteh effeet at the poinbl of eolumn mounting,
as well as suffieient pre-stressing of the upper eolurnn end part against
a shoulder whieh rests inside the top platen. Thc conneetion with thc
base platen i8 executed as per fig. 32d.
The elearanee of the eentering surfaees inside the lugs is to be kept as
small as possible as it favors thc so-called shaking of thc pre8s during
forging operation. Depending on thc achicvable accuracy of the column
centers in the platens, a clearancc of 0.040 iL to 0.080 in. will usually Le
required. A 8eat without clearance may be applied if the eolumn eenter8
are kept equal by u8ing a boring jig.
The eolumn nuts are split and consist of either cast steel ASTM A-27
GR 60-30 or steel ASTM A-7. The bearing 8urface of the nut is to be
ehosen as to not exeeed a bearing pressure of p = 11,500 psi. lf D equals
the outside diameter of the nut, d the major diameter of thc thrcad and h
the nut height, the column nuts may be madc according to thc well-
proven relations D = 1.5 d and h = d to 1.2 d.
The nut halves are kept together by bolts; their total are a at root of
thread is made abt. 6 to 8% of the are a at column root of thread. The
stress ealculations for the bolts are elimina1ied, as the resultant actions
in the thread and in the bearing surfaee of one nut half Jie within the root
area of the cross-section. Therefore, the two nut halves eannot fali aparL
the pressure, however, is unevenly distributed over the bearing surfaec.
In order to bring the resultant actions into one axis, it has been tried to
make the nuts of oval shape, but this design has sinee been abandoncd.
For adjusting the outer nuts, they are provided with radial rod holes.
The (inner) eounter nuts are equipped with several bosses in order to
enable tightening by hitting.
4. Press Cylinders and Rams

The nominal press load is figured as a produet of the effeetivc ram
area and the highest pressure created by a pressure station. Both factor8
have to be eonsidered with re gard to the economical point of view whcn
designing a press installation. High fluid pressure in particular enhance"
the advantages of the hydraulic power transmission as eompared with
the applieation of meehanical means. Therefore, the fluid pressures in
press cylinder usually range from 3,000 to 6,000 psi.; the prestlure figure::;
as suggested by the German Standards Association 1 ) are to be preferred.
The fluid pressure for forging presses with accumulators is mmally not to
exceed 4,500 psi. in order to keep wear of valves and control gears, duc
to the inereased loads and aiI' and gas absorption (see "Prestlure Fluids"),
within bearable limittl.
1) DIN 323, Standard Numbers.

The ram diameter is already determined by the chosen pressure and
a given nominal press load. The ram, which is guided and sealed at the
open end of the cylinder, must have sufficient clearance in theremaining
interior of the cylinder. This clearance depends on the condition of the
intern al cylinder surface and should, for instance, not be less than
0.875 in. in diameter in case of a cast steel cylinder with a ram dia-
meter of 32 in.
The inside diameter thus determined is the basis for calculating the
wall thickness required.
Due to the internal pressure a triaxial state of stress arises in the wall
of a closed cylinder which is designated by the tangential stress St, the
radial stress Se, and the longitudinal stress Sz. If no residual stresses or
other stresses exist, and if the deformations remain within the elastic
limit, the stresses caused by the internal pressure may be determined by
BACH'S formulas given in formula table 1. These stresses are plotted in
fig. 34. While the tangential stresses St and the radial stresses Sr ha ve
their numerically largest value at the internal fiber and rapidly decrease
towards the external fiber, the longitudinal stresses Sz are the same ali
over. Considering the sign, it is St > Sz > Sr.
:Formula Table 1. Strcsses in the Cylinder Wall at Exclusively Elastic Deformation

(according to C. BACH)
I.'Q I' th c iJ'1l r liber Fo r th c Olltl'l' tHwr
t'j = Pi
(longitudinal str sses on l)' ari e in

s" = s," = 8,. = - 1), u2 _ 1 ,. closeeI cylinde"s" , ce p.41)
do = outside diameter,
d i = inside diameter,
d" = diameter in relation to any point x,
P; = internal pressure.
Compressive stresses as wel] as the internal stresses Pi bear the negative, tensile
stresses the positive sign.
In addition to the stresses caused by the internal pressure, as a rule,

further stresses arise in press cylinders due to their shape or kind of
cylinder support and which, therefore, have to be determined separately
by way of the normal calculations. Thus, e.g., additional stresses arise at
the openings for pressure fluid feed and return as well as at the cylinder
support or by the loads and moments resulting from the columns. The
40 FORGIKG PHESSES
various stresses thus determined are added algebraicaJly to thc sum of

the tangential, radial, and longitudinal stresiles. In doing so, the CI'itical
points of the cylinder show up for which Il
stress calculation would be rcquired.
In order to judgc the stability of the cylin-
der by way of th,~ determined stresses of it
+ triaxial state of stress as per formula table 1,
the elongation thcory was applied for a long
time, according to which the material strCSi-l
has to be comparerl with the rcduced strcss
8, + s,
J SITe = 8t-
In
(m = Poisson's rutio, for stcel: n/. = ~~)

Fig, :34. Pl'ogress of strc~::,eR in which must not. exceed t.he aIlowahle tensile
the cylindcrwall (as p('rfol"lnul:l stress Sa'
table 1).
The shear stress theory, stil! frequently
heing used, assumes that, on the other hand, the difference from the
largest and the smal!est main stresses is to 1Ie considercd as the valw: of
the actual material stress
Nowadays the theory of deformation ie: most commonly employed

aceording to whieh the material stresscs are expresscd hy the comparison
stress
1 ., - - - - - . - - . ---
Se = - _ HSt - sr)2 + (S,. -- 8{)2 + (s/ - StJ2
12
the allowable value of which is also limite(L hy 8" of the material used.
The theory of deformation requires, undeI' otherwise cqual conditions,
a slightly thicker wall than the theory of elasticity and a somewhat
thinner wall than the shear stress theory. It comes, however, c!osest to
test results and shall be exclusively employed in these chaptcrs.
The above equation for Se usually holds true for any values of thc
single stresses. It is to be employed only if single 01' alI thrce main
stresses arc composed of a sum of superimposed stresses duc to simulta-
neously acting loads.
In order to visualize the sizc of the "comparison stress" s,. with givcn
stress components, the afore-mentioned equation may he graphicaIly
solved as per fig. 35.
The calculation is considerably simplified if the cylinder is only
stressed by the fluid pressure and no other OI' mercly negligible stresses
exist, i. e. if only the stresses as per fig. 34 have to be considcred. In this
connection we differentiate between c:Iosed and open cylinders.
Generally, a cylinder which is inserted into a platen and which backs
against the platen with a shoulder near its open end, bears the requisits
]<'ig. ~5. Graphiea l ,ollition of thc formula for the

compari"on stress aecordinll to the theory of dcfor-
mation:
Se _ __
8e = -~'1(8t - s, )' +Ts;." - 80'+<8, - s;)i .
0- '
12
+ . -.- ~ _._ .
Ifthe main stresses 8" S, ano 8, are plott.,.1 aeconl-
ing to their sign starting rrom the basis II, ami
if tlte differenee of two main stresscs is IIsed as
basis of an eqllilateral triangle, then 8e may be
mcasured as the distanee from the pointoftriang1c
to the vector end point ofthe third main dimcnsioJl.
of a closed cylinder without additional stresses. In this simple case we

have the relation (see also fig. 34):
For any point x, this formula changes over into the simple equation:
or, with reference to the internal pressure:

./ - u.c 2
8e = - pi}3--
x u2 - 1
Open cylinders are those which back with their bottom against a
support. It is characteristic of these cylinders that no axial forces are
transmitted through their wall. The commonly used formula for calcu-
lation is employed, but with Sz = O, as a result of which the also commonly
employed formula arises for the biaxial state of stress, for any values
of 8 t aud 8,:
8e =
x
V8t 2
x
+ 8, 2x - St Sr
x x
for any point x, or, with regard to the intern al pressure, but employablc
only if no additional stresses exist:
Under otherwise equal conditions, the comparison stress is higher

for open cylinders than for closed cylinders, which consequently entails
an increased wall thickness.
The graphical solution of the formula Se' X = V8 tX 2 + Sr X 2 - St X 8 r x rrlaY
also be found as per fig. 35 by equating Sz = O.
42 FORGING PRESSES
~OM~\~~'~
\ ~~~~~~~~
\ ~~~-+~~++~~~
l \' \\\\ \ '\
a) for the closed cylinder

Fig. 30. l~clation~ between internal prcssllrc Pi, (\iametl'r l'elationshil' "
The formulas for the comparison strcss 8 e , according to the theory of

deformation, and the derived relations bet.ween 81' and 'U for closed and
open cylinders, loaded merely by internal pressure Pi, are tabulated in
formula table 2. The relations with regarcl to the int.ernal fiber of t.he
cylinders according to formula table 2 are plotted in fig. 36.
It is frequently desira bie to keep the outside diameter of the press
cylinder as small as possible to facilitate operation with a crane.
Z$,ooo"\ f, ~~~,
"\ \ f\ '\ 1\'1\' \\\\\\\'
\ \ \1\ \ l\ · \\\\\\'1 \\\\ 11-

Z/J,OOOJl.-f\....l,\-IlH-l'\I,...\!..\
,\ \.:ţ.\.;\I\..lJ'.1,ţ
\\\\ \\,\W \\\>,\W
\\'\\\\1.\'\ \\ \ +\~\,......4,-I\-\I\~>.rl--*'\+-f-++...p.J.,Nt't'..d
'\ \ \1\\ .\\\\\\\' \\\W \ 1'\ 1\. 1fi-
\ T\ \' \ \\\\\ \' ,,\\\\ ~\ 1\ 1\ 1\ 1\ I-f"'a
1\ \ '\ \f\1\ \ m\\\'l\\\\'\~\\ \ \ 1\ \ Irf
'\ '\ -\1\1 , \ \ \'l\\\\'t\\\'\
\\ 1\ 1\ '\ ~
do
lL=di -
b) for tbe open cylinder
and comparison strcss sCi at the inncr liber of the cylindcr wall.
Considering a required press load of P = :Zi::iT .Pi, the internal dia-

meter di becomes smaller the higher Pi is chosen. Thus the outside dia-
meter becomes smaller only up to a limit that depends on the permissible
stress of the cylinder material, and from there on becoming larger again
as Pi is increased still further in order to de crease di . For a material that
permits a certain stress Sa, there is, therefore, a certain internal pressure
44 FORGING PRESSES
Formula Table 2. Compurison Strp88 According to thr l'hmry of Deformation

a) for the Closed Cylinder (Triaxial Stress Condition)
I stress
good for any triaxial
condition
for t he innet' fiber
r;" U ,t;2 good for t he t ri axial

for any point x 8, = - Pi 13 -u0-
.L ~-
-
1 stress condition due to
p, alone
- 1
for the outer fiber seo = - P. 13 u 2 -- 1
b) for thc Open Cylinder (Biaxial Btress Condition)
good for any biaxial

stress condition
-------
for t he inner fiber I
13u~4 +1 good fo r the biaxial
for any point x 8,~ = - p, u2 _ 1 stres condition du e to
p. alone
2
for the outer fiber 8,. = - p, u2 _ 1
do = outside dialllcter,
di = inside diallleter,
dx = diallleter with regard to any point x,
Pi = internal pressure.
Compression stresses, also the internal pressure Fi' beaI' the negative, tcnsion
stresses the positive sign.
[l,: to whieh is assigned the smallest possible eylinder outsidc diameter

do. This rclation is
Sa
'[li=- .'
2p
If, for example, the allowable stress Sa = 16,000 psi., then the smallest
16,000
outside diameter of the eylincler is being: gained at [li = -
~ 2P
= - 4,620 psi. internal pressure, while at a higher or lower internal
pressure a larger outsidc diameter would be required for the same press
load.
Fig. 87 shows besides the permissible stress Sa also the internal prcs-
sures [li, or the pressure stages as per German standards R ] O rC8peeti-
vely, whieh give the smallest aehievable outsicle diameter of the press
eylincler.
Calculations made according to the preceding rules only give the

nominal stresses and neglect all influences, which cause stress peaks.
If there are any changes of cross-sectional are a perpendicular to one of
the three main stress directions, such as notches or holes, then the thus
developed local stress increase is to be considered by employing the
stress concentration factor IXI).
Therefore, when determining the
comparison stress 8 e , the main
stress in question has to be sub-
stituted by the amount of 8 max
= (X · 8.
13,000
1U,000 psi
psi
1flOOO
J
t
~ 30,000
...
~ ~OOO
~
11
.~
~
I
~ 20,000
C,OOO
'1;000
10,000
2,000
}'ig. 37. Smallcst outside diamcter of a closed I·'ig. 38. Press cylindcr aud rams witlt ]lress ro,l
cylindcr at a givcn ]lress loud due to ada]lting coun€ction to llloving crosshcad. (By: Hydraulik,
the material to the internal ]lressure. DuisLurg.)
On the other hand, in case of a big stress change a supporting effect

of the neighboring fibers 2 ), which are not as highly stressed, takes place,
thus requiring a relatively low safety factor SF for the strength (fatigue
limit) 8j of the material.
The wall thickness of the cylinder bottom depends on the bottom
shape. A hemispherical bottom, which is frequently desired for cast or
hollow-forged cylinders with swaged bottom (figs. 38 and 39), may be
calculated as per formula
3 u 3 3)
8 ei = - Pi 2 ·u" ..... 1
1) See Rutte I, 28. Aufl., p. 960.
2) SIEBEL, E.: Neue Wege der Festigkeitsrechnung. VDI-Z. 90 (1948) S. 13iHf. -
SCIIWAIGERER, S.: Werkstoff-Kennwert und Sicherheit bei der Festigkeitsrech-
nung. Konstruktion 3 (1951) R. 8.
3) See Rut-te I, 27. Aufl., p. 733, and 28. Aufl., p. 951.
46 }'ORGING PRESSES
and would amount to haU the cylinder wall t = ro - ri under samc strcss
conditions, considering the usual pressure range Pi = 3,000 to 6,000 psi.
Fig. 39. Hollow·forgrd press eylinder, ICllgth ](i ft., lar~est outsidc di:lIlletcr 90 ill., wcight approx.
UU,UUU Ihs. (ily: Hydraulik, Duislmrg.)
and a material equivalent to the pressure. Aflat bottom calculated 1 ) as a

fixed plate as per formula 8"lllX = 0.68 (~iY Pi would have to be made,
within the same pressure range, about 1.5 to 1 times the cylinder wall
thickness. UsuaIIy, the bottom is compound-curved, the internal radius
- di between wall and bottom is made r ~ ~i.
and the bottom thickness 1.5 times the
cylinder waII, eliminating an exact calcu-
lation and taking into account the influence
of shape due to connecting holes and bores
in the bottom.
For transmitting the press load P
created by the fluid pressure onto the cylin-
der platen, the cylinder is provided with
a shoulder carefully machined at the radius,
in order to decrease thc notch cffect and
thus the danger of fatigue fracture. Dimen-
c sions of shoulder and seat may be based on
the following empirically derived values (scc
fig. 40):
tI = 1.1.5 t, Q = 0.2 to 0.3 t,
Fig. 40. Shaping of,houldcr nt
eylinder plakll. Z" = 1.5 t, h = 2.:n
1) BACH, C.: Elastizităt und Festigkeit, 8. AuiI., S. (ilO, Berlin: Rpringer Hl20.
The seat width b, starting at tI + e, is to be chosen such that the

bearing pressure between cylinder shoulder and platen does not exceed
the maximum value of p = 11,500 to 13,000 psi., taking into account
stud holes or other interruptions, or p = 10,000 to 11,000 psi. in case
of eccentric forging loads.
For calculating the shoulder, the basic formula as per DIN 2505 1 )
is used:
M1' M
81' 2n8-R-
where:
M1' means a material factor. For repetitively stressed cylinders, the fatigue
limit of the material is used: M1' = 81;
8F means the safety factor. In case of repetitive stresses, a safety factor of
81' ~ 2.2 against fatigue fraature is suitable, but it should be aimed at
81' = 3 to 4 because of pos~ible shock loads and uncertaintics in the load
assumptions;
NI
2- means the induced moment, with M = P·a for the assumed critical
n t b
point at section A - A, where a = tI - 2- + e + 2 . It wouldbeadvisableto
add a 10 to 20% supplement to P for cylinders, which take part in the
transmission of the moment resulting from eccentric forging loads.
8R means the shoulder resistance - a value with the dimension of a section
modulus - for the section A - A, for which DIN 2505 presumes the fulIy
plastic condition as being the critical condition; if only elastic defor-
mation is permitted:
with Al part of the cross-sectioned area separated by the neutral

=
fiber c - c as per fig. 40,
and el = distance of center of gravity of area Al from c- c.
(It is: Al el = A 2 e2 ·)
With the preceding values we attain an analytical safety against

fatigue fracture of
The mounting bolts for the press cylinder have to take, besides its
own weight, also the weights of aU moving parts in case the ram jams,
and for three-cylinder presses, moreover, the loads of the side cylinders
which are under prefill pressure.
For guiding the press ram, the cylinder is equipped with a long bronze
liner. If loads must be taken up, which become effective at right angles
to the press center line, the length of liner is dimensioned such that the
bearing pressure does not exceed 400 to 700 psi.
1) DIN 2505, Berechnung von Flanschverbindungen.
48 FORGING PRESSES
For sealing the plungers, soft packings as per fig. 41 wcrc used in
former times, which were inserted into thc packing space and compresscd
by an adjustable gland ring. The required packing depth is choscn to be
8 times the packing width for pres-
sures up to 3,000 psi. and 10 times
the packing width for pressures
above 3,000 psi. Packings of this
kind seal by radial pressure acting
on the plunger surface due to gland
Fig. 41. Interwoven soft parking of hCn1p aIlrl ring compression and, therefore,
coUon soakeLl in tcmpcring oiI. (By: lIIt'l'kd, causc high friction losses.
lIamburg.) ~
The amount of friction cannot be

determined accurately as it depends on several variable factors 1 ). These
factors are mainly the condition of the ram surface, the kind of lubri-
cation, and the packing material and above alI the comprcssion by the
gland ring.
A rule of thumb for determining the frietion resistanee, whieh has
been developed from experienee and whieh is being used frequently,
is Rj = 1), . A . c . p. A = d· n . h1 indica tes the are a of eon tact between
plunger and packing and c· p stands for the medium radial compression,
whieh is required to scaI against the operating water pressure p. For
soft paekings usualIy fk = 0.2 to 0.4; c = 0.15 to 0.3.
For about 20 years lip packings which can be used for water as well
as oiI (table 6), have been used to se al rams. vVith these "self-sealing"
paekings, the lips are pressed against the plunger surface by the pressure
op the operating hydrau-
lic medium. At least
three rings are placed
behind eaeh other.
Lip paekings as per
table 6, form A, are only
slightly tightened by the
gland flange. The "ad-
Fig. 42. Vnlcanizcd lip packing with plics of [abrie. justment" (squeeze) is
(Hy: Merkcl, lImnbnrg.)
filled with spacers, sa
that the gland ring nuts can be tightly turned, the gland is adjusted only
for eompensating the wear of the paeking rings. The rings are supplied
cliagonally cut, sa that the paeking can be installed without removing
1) BLASER, H.; Dynamische Probleme beim Schubkolbentrieb. Mitt. der v. Hol!-

schen Eisenwerke AC, Gcrlafingen, 1957 H.I-4. - Hopp, H.: Untersuchungen
uber den Reibungswert von Dichtelementen fiir Hubbewegungen. Hydraulik- una
Pneumatik-Technik 1957 H.2. - LUBENOW, ~W_: Beriihrungsdichtungen an be-
wegten Maschinenteilen. Konstruktion Il (1959) H. IL
FORGlNG PRESSES OF MOVING-CROSSHEAD DESIGN 49
the ram. Sometimes the lip packings are provided with soft metal
inserts, in order to de crease the friction (fig. 42); these inserts form
a closed metallic surface in axial direction of the plunger after run-
ning in.
For higher pressures and particularly for horizontally arranged
plungers, chevron packings are preferably employed (table 6 form B).
These packings are supplied either as a whole ring or diagonally cut and
may be under slight compression between the front and back support
rings, when the gland flange is positioned tightly. The friction resis-
tance is slightly higher as compared with the lip packings according to
form A.
Further modes of application to suit the various conditions of opera-
tion should be taken from the manufacturer's instructions. For lip
packings textile fabric of long-fibrous cotton is used which is vulcanized
in pressure molds together with mixtures of caoutchouc. There are
various figures on the life of the vulcanized fabric packings, as the con-
dition of the plunger surface and the lubrication are important factors.
A life time of several years has been observed where measures to prevent
dry-running had been taken. There is a danger of dry-running, parti-
cularly when planishing with many consecutive strokes, which are
smaller than the packing length, where no moistening of the plunger with
hydraulic liquid for lubrication and cooling takes place. It is recommended
in this case to use a larger intermittant idle stroke, if no forced-feed
lubrication is provided.
The friction resistance of chevron packings may be approx. deter-
mined by the above-mentioned relation W = fh·F.c 'p, where fh = 0.05
to 0.06 and the coefficient c is assumed to be about c = 0.15 on account
of the high pressure drop towards the outside diameter.
For sealing the oiI pistons, also self-clamping piston rings and spring
ring packings (table 7) can be used, it must be considered, however,
that with these sealings a certain little oilleakage takes place that may
cause an unpermissible movement of the ram when the press stands
stiH. The leaked oiI is collected in a pre-chamber and returned into the
oiI tank. A reduction of press capacity due to friction losses can hardly
be noticed with piston rings and spring ring packings and may, there-
fore, be neglected.
For water operation, the gland flange is provided with a bronze
liner and with at least two threaded holes for puller screws. For oiI
operation and when using spring ring packings, the gland flange ring,
with only little centering, is tightly screwed against the packing. Puller
screws are, therefore, not necessary in this case. The gland ring is provided
with a pressureless chamber to collect the oilleaking through the pack-
ing; this chamber is sealed with wiper and sealing rillgs.
4 Miiller, Hydraulic ]<'orging Pressrs
.50 FORGI NG PRESSES
7[
I'l/.
'<>
.,.:,e.,.""
:;o
Ci:
Q
"
o...
.~
~
.2,
.,'" El
11.
""§ El
.S
"'"
C,) rn
.:: c.
o
~ '00
~
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.::
~
~ ;OS
't>
.§
~ $
'"..,
:::: 11.
.~
~
~
::o
~
:-;'"
~------------------ 7[ ------------------~
~---------------- 11. ----------------~

~--------------_ I'1/. --------------~
Pro fllc
... ))imllctcr A Jl c ]) H
* T:lngC Willlil
fi II,
r I h1 ", 'Tl 1'1 ItI
a_ IIIl la IJ ~III. ". r 1 II, ". -.-1-
/ ·7'"7"""''--- 6 40 24 4,5 1,5 1 "'i
vV~ .~ 10,52_1 O
!:ti
25 8 48 28 5 2 35 12,4 2,.5 1,5 Q
.....
Z
I
80 10
~I---= 34 6 2,5 140 12,5 2,5 4 2,5 Q
"ti
125 12,5 80 40,5 7 3 510 16 3 5 3 !:ti
- 1-
t'l
W
200 16 100 w
49 8,5 4 I~ 18 .!--'~ 3 t'l
~ w
450 20 - 1281128 24 5,5 164 Il 5,5 70 22 4 7 4 O
~ "'i
1000 25 160 150 30 7 ~
O
over 30 1200 1200 35 9 -<
1000
Z
Q
Pack ing PIl\stics with cotton fabri e,
LcathCl· o
material profi le vulcanized !:ti
O
gl". w
w
FOI"n1 of supply ning or linear R ing R ing ~
t'l
~ :.-
~ ti
:::. R en1l1rks Application for slolV speeds, short
~ ti
strokes, usually not exeeeding t'l
W
3,000 psi., in every case 3 ri ngs.
Sensitive to !leat. i5
z
Abova t.able ShOW B dimensions h l for pressure ranga 1,500 to 4,500 psi.
Pressure fa.nge psi. up to 1,500 up to 4,500 up to 9,000
-----
Number of effeetive lipa n :3 4 5 _ _ _ o
1- 01
Sea.t of gland bushing h - 71) ]. 2 b 1.5b 1.8 b .....
52 FORGING PRESSES
Table 7. Dimensions of Piston Rings and Piston Ring Packil1fJ8

(Goetzewerke, Burscheid)
Dimensions in mm
--1 d~
I~ E' a~
01>
~ Puc/ring ring
I~ OtJ
Spaur
I .."'-~, ·Spacer
o--<:! d~
I
fisfon rod d D (1+ x It b II
40 60 40,1 49 50 5
I 70
100
86
122
70,1
100,1
77
110
78
111
5
6
I 150
200
250
181
240
299
150,1
200,1
250,1
165
219
166
220
8
10
.~ 274 275 13
300 353 300,2 326 327 13
400 465 400,2 432 433 16
500 580 500,2 540 541 20
600 699 600,2 650 65l 25
700 820 700,3 760 762 30
800 920 800,3 860 862 30
900 1020 900,3 960 962 30
D d h, h, b
40 36 4 2 0,9
70 6:~,4 6 3 1,6
100 91,4 8 4 2
150 137,4 8 4 2,5
200 183,8 10 5 3
250 230,4 12 () 3,5
300 276,4 12 6 4
400 369,2 14 7 [;
500 462 16 8 7
600 554,8 18 () 8
700 647,6 20 12 9
800 740,4 20 12 10
900 8:33,2 22 13 11
For calculating the gland ring according to DINl), it is assumcd that

the maximum internal pressure acting on the packing width is trans-
mitted to the gland ring ftange.
As spring ring packings require a larger width than chevron pack-
ings, the gland ring ftange dimensions have to be increased accordingly.
1) DIN 2505, Berechnung von Flanschverbindungen.

FORGING PRESSES OF MOVIKG-CROSSHEAD DESIGN 53
The pipe for feeding the hydraulic liquid into the press cylinder is
usually arranged at the prefill housing in the chamber above the valve.
Therefore, the prefill valve is either arranged close to the press cylinder
or in the cylinder bottom, in order to obtain a short connecting line,
and the cylinder connection should preferably be in bottom center. The
ram may be provided with a throttling rod which protrudes into the bore
of the cylinder bottom, causing a retarding movement by narrowing
down the exhaust aperture.
When designing the cylinder, care must be taken that no air occlu-
sions can occur, which would create shocks in the piping and cause an
uncertain plunger movement. In many cases the occluded air can be
exhausted easily into the prefill vessel or accumulator by performing a
few idle strokes of the rams. From oiI actuated cylinders, the occluded
air discharges into the pressureless leak oiI chambers after a short period
of time. Where such a self-venting cannot be anticipated, venting screws
are arranged at the highest points of cylinders, piping, and control
gears (fig. 43). Furthermore, bleeder screws may be provided at the
lowest points, e.g. above the cylinder liner, so that the operating medium
can be drained for repair works, OI' for an extended shut down period,
or during freezing periods.
The cylinder may be either inserted into a bore of the cylinder platen
(figs. 19 and 38) or integrally cast with the platen (figs. 44 and 45). The
decision for one or the other kind has to be made with regard to design
and casting technique. The platen with integrally cast cylinder render,.;
possible a compact press, but entails stress concentrations at the points
where the forces are transmitted into the column lugs. When designing
the press, care should be taken that the cylinder wan is accessible, so
that porous points, which arc not necessarily critical, can be eliminated
by peening over OI' welding.
The ram should have a hard, smooth and homogenous surface, the
material frequently being AISI 1045, flame-hardened, OI' chill casting.
Moreover, nitriding and chromium plating of the surface OI' spraying of
Cr-steel on to a prepared surface have given satisfying results.
There are three different applications for fastening the ram to thc
movable crosshead. The plunger i8 either firmly inserted into the cross-
hcad or scated on a sphcrically machined thrust piece or connected to
the crosshead by a pressure rod. The determining factor for choicc of
these applications is the behaviour with regard to the lateral and ecccn-
tric forging loads. As the movablc crosshead must have ample elearancc
in its column guides in vicw of its clongation due to heating, a corre8-
ponding lateral movement and a slight inclined position are pos8ible.
In case of a rigid connection between plunger and moving crosshead,
the whole moment exerted by the press 10ad may have ta be taken by the
54 ,FORGING PRESSES
..""'
~
c.> I( ~,~'"
H': ~
~'
c-.tM
'0-"":'"
~ <.>
1:::: C'l0
-=E
0'" '"
C'lM
°E ..:: M t-
tQ C
i~
.,,"
", -
...... \0
='"
-"
~.2
'" ............
O lO
.."''''= ~ C'l c-.t
a~ ...... M <--
.:l:' ...... .-<
~6
"-,
-1i
"
...... 0
'" bO
"",,, '<l' lQ c:r..
.3 '<5-
Q'j5. .:i
M ....
M'<l' **"'""
" ",
>=
~
.j2?
.. "O ~
~~ c:,
"t:
.. ., lq,M <
"''O
~c
'€ c-.t c:r..
=;;::
.... *"'""
:S. .,
~
**
.
.. <'> "''<l'
.-< C'l
'€
~ ~ 00,",
--i .-<
,, ~
"''''"
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C .'::
:=d --i -.:fIle
§Q
;....~
C'l C'l
" .-
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X X
--i 00
.....,. .,
....:.~
."
00 0
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~~
C'>J:.::l
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...... C'l
> ~ ....
1<; > ~
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.....
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"," ..
'€
;s ~
o <l>
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c
~ P-<.c
i;:; ;::l
'"
ram - and subsequently - by thc cylinder liner. This causes great wear
of the liner and may result in scoring of the plunger and leakiness of thc
packing. Therefore, the rigid connection is seldom employed and not
applicable for multi-cylinder presses because of the uneven heat elon-
gation of moving crosshead and cylinder platen.
FORGING PRESSES OF MOVlNG-CROSSHEAD DESIGN 55
If the ram is seated in a spherically machined thrust piece, which il:'
arranged with lateral clearance in the moving crosshead, only friction
forces and friction moments can be transmitted through the ram into the
cylinder liner, in case the moving crosshead should move laterally 01'
tilt; these friction forces and friction moments may, however, reach the
1<'ig.44. 2,200-ton forgiug aud closed-dic press for accumulator :Fig. 45. Cross-scdion through
operation with integrally cast press cyliuder and top platen. press cylinder, fllling devier.
Operating water prcssure 3,000 pei. (By: llanning, Hamm.) and puII backs as per fig. 44.
values of dry friction because of the difficulty of grease distribution and

thus strain the stuffing box considerably.
AIso, if load transmission by means of pressure rods is concerned.
only friction forces and friction moments can be transmitted. In thil:'
case, the spherically machined rod heads allow for both lateral shifting
and tilting of the moving crosshead. For assembling purposes, the pres-
sure rods are retained in the plunger by a ring. Permissible bearing pres-
sures for pressure rods and spherical seat are 14,000 to 18,000 psi.
For plungers which are hollow-cast 01' bored out, the stress at the
inner fiber must be calculated, because of the externally acting hydraulie
pressure, by the equation
56 FORGING PRESSES
the required diameter relationship is
,u >}/- - --8,,-
= Sa - Pa]3
in which
8" = allowable compression stress,
Pa = hydraulic pressure.
s" and po are compression stresses and bear, therefore, the negative
sign.
The equation for sei is analogous to the equation for the stress of thc
closed cylinder (see p. 44). Therefore, for calculations the chart on
p. 42 may be used.
5. Moving Crossheads
The moving crosshead serves for guiding the ram at the columns amI
for transmission of the ram load into the upper forging die. For mOUIlt-
ing the upper die, the moving crosshead may in simple cases be provided
with a wide slat (key seat) and several mounting slots. In most cases
and partieularly on large presses it is feasable to provide for exchangeable
mounting surfaces of diflerent sizes, so that the standard tools as well as
the occasionally outrigging tools can be properly mounted. Furthermorc.
it i8 advisable to eliminate the wedged groove at the bottom side, if the
moving crosshead can come to rest on the protecting jackets for the
columns, which would cause high bending stresses. This led to mounting
a heavy die plate to the smooth hoUom surface of the moving crosshead
(fig. 46). To this die plate either a large or small die foot may be bolted,
as occasion demands. The IaUer is provided with slatE; and other mount-
ing devices, and a centering bore to facilitate mounting of the different
die shapes. \Vorn-out slats at the die foot may be remachined withol1t
any difficulties.
The width of the moving crosshead should be as narrow as possiblc,
in order to facilitate handling of even short ingots between the dies with
cmne chains; usually the width is adapted to the width of the cylinder
platen where the same requirements have to be met and where the out-
side diameter of the cylinder is the determining dimension. In some cascs
the front faces of the moving crosshead are provided with machined
surfaces, e.g. if the press is to be used for making wide drums (fig. 47), for
receiving consoles so that thc thrust piece - which is mounted under-
lleath the movillg crosshead for opening out - ean be kept low.
For transmitting eecentric forging loads, the moving crosshcad must
be properly guided. There are two different applications, i.e. moving
erossheads either with column guiding only orwith combined eolumn- and
eE'ntral guide stalk.
>rj
O
:,;
ez
C"l
'1i
:,;
trl
ifl
ifl
trl
ifl
O
>rj
s:
O
::1
z
C"l
()
:,;
O
ifl
ifl
::r:
t:r:
;,-
d
d
trl
ifl
8
z
Ot
-.]
Fig . .16. lG,500·ton three-cylinrlcr [orgillg preRS for acc\llllul"tor operation with lower pullback- a.nd
uppcr balanciIlg cylinclers, lung columlls, and flrxihle luad tran:-:.missiol1. (By: Hydrau1ik , Dui~burg.)
58 FOHGING PRESSES
The first-mentioned application is the simplest one. The column lugs

are made as long as possible; they receive at both ends split bushings
of soft cast iron or bronze (fig. 48).
l'·jg. 47. Stcam-hydraulic 2,200-ton forgillg press with intrnsifler making a tnrbinc drum. (11)-:
Hydraulik, Duisburg.)
In order to obviate any end pressures if the moving crostlhead shoulrl

tilt and to utilize the whole bushing surface, their outside diameter is
frequently machined spherically and inserted into a split (two-piece)
bearing box (fig. 49). Due to heat elongation of the moving crosshead
during forging operation, the columns are provided with clearance in
the guide bushings; this clearance can be determined from the tempera-
ture rise of usually 2]2 to 300 oF, which is known from experience.
At room temperature the bushings rest with their outside diameters
against the bearing surface of the columns, while there is about the
same clearance at the inside and outside diameters during operation.
l?ORGING PRESSES OF MOVING-CROSSHEAD DESIGN 59
One-cylinder presses with their ram being firmly inserted in the

moving crosshead have no exclusive column guiding, as the plunger will
counteract the tilting of the crosshead and thus transmit the loads
Fig. 48. Column guiding with split Fig. 50. Thrce-piecc moving crosohcad of a 1~,200-ton
cylindrical bushings. two-cylinder forging press witlt combined colullln- and
stem guiding (as per J. lron Steel Inst., March 1949).
Fig. 49. Column guiding witlt split Fig. 51. Moving crosshead of a 13,200-ton three-cylinder
splterical bushings. forging press with combined column- and stem guiding.
(By: Schloemann, Diieseldorf.)
60 FORGING PRESSES
- due to eccentric forging - into the cylinder liner. This causes consider-
able wear, often resulting in leakiness of the packing. The advantage,
however, are short column lugs.
The combined column- and stalk guiding was employed by Messrs.
Davy in Sheffield as early as 1886 and is shown in figs. 50 and 51, special
feature being the central guide stem. The eccentric forging load is thus
Fig. 52. Stealll-hy(lraulic 6,GOO-tOIl two-eylillder forging JlfCSS with ('onlldned ('ohmll1- :llId :. ,ja!k
g:l1idillg of tlw lllOYÎUg rTosshead, indelWllllently lllOvahlc dip lllatt~~ aneI two ::itt'nTn jllt(\l1~jft('r~. (Hy:
Davy Brs. Ud., SheffteJd.)
transmitted to a long lever arm, so that the bcaring pressurcs Oll thc
columns wiU be relatively low and the guide can be kept very short.
The guide stalk is either integrally cast with the moving cros8hcad
(fig. 52), OI' inserted into the crosshead as a cast steel- OI' forged Rteel
piecc. The split guide bushings at the head and in the column lugs arc
seated either stationary OI' spherieally.
Moving erossheads with central guide entailed the two-cylindcr
design for forging presses, but they are also sometimes empIoyed for
three-eyIinder presseR. They are used almost onIy on presses exeeeding
2,200 ton capacity.
Three-cylinder presses with central guide stern are wider than two-
cylinder presses, as the rigid stern has to be arranged in the bored-out
plunger.
Fig. 50 shows the three-piece moving crosshead for a 13,200-ton
two-cylinder press with inserted cast guide stern, firmly arranged split
guide bushings at the columns and spherically seated bushings at the
guide, as well as pressure rods for transmission of the loads. A similar
moving crosshead for a three-cylinder press is illustrated in fig. 51; in
this case the guide bushings in the crosshead column lugs are also seated
spherically.
On these designs, the loads which result from eccentric forging also
create bending moments in the columns. 1'he material for the crossheads
should only be cast steel (ASTM A-27 GR 60-30). The nominal bending
stresses in stress calculations should not exceed 6,500-8,500 psi. Some-
times design specifications ask for the moving crosshead to take the
whole press load, if the column lugs rest on the column bumpers in the
lowest position. This makes the moving crosshead and the protecting
jackets unnecessarily heavy; these conditions are not feasable for presses
with large column centers; control measures should be employed in-
stead for preventing the moving crosshead to come to rest on the
bumpers.
Usually, crossheads weighing up to 110 tons may be made one-
piece. If this weight is exceeded, it should be checked whether - for
reasons of transportation - the crosshead should be of multiple-piece
design.
The permissible bearing pressure in the guide bushings is generally
chosen 850 to 1,300 psi. For lubrication of the bushings, an oil-graphite
mixture is used which is applied to the guiding surfaces. Felt rings above
the guide bushings for wiping and distributing the oiI have not proven
successful, as they crust easily due to the heat. Large presses are equipped
with a central forced-feed lubrication.
Fig. 53 shows a moving crosshead with prismatic guide for a 7,700-ton
forging press of English design. The columns are surrounded with split
sleeves over the whole length between base and cylinder platens; these
sleeves have right-angled sliding surfaces. The guide sockets at the
moving crosshead can be adjusted in both directions by the help of
wedges. The advantage of this kind of guiding is the adjustability of the
sockets after wear, while cylindrical bushings have to be replaced. In
spite of this fact, the prisma tic guide could not prove itself due to high
initial cost. Other designs, e.g. wedge-type adjustment for cylindrical
guide bushings as used on friction bearings, did not prove themselves
either. The reasons were the rough operating conditions, which require
simple construction.
~
t-:i
"'J
O
:tl
o
,...
z
o
"C
:tl
l'J
w
W
l'J
W
:Fig. 5:\. )Ioving crosshead for" 7,700-ton one-cylilldcr forging prcss with adjn stal,lr pri smatic gllidcs (as per J. Iron Stcd lnst., Febrllary 1949).
:FORGING PRESSES OF MOVING-CROSSHEAD DESIGX 63
6. Return Devices
The return loads must be determined to be capable of

1. lifting and accelerating the self-weight of the moving parts,
2. overcoming the pressure of the prefill vessel acting on the press
ram with usually 60 to 70 psi.,
3. achieving a sufficient return speed (which may be limited to about
12 in.jsec. by throttling) taking into account the flow resistances, parti-
cularly ;hen planishing with closed prefill valve,
4. occasionally lifting a workpiece.
If the return and forging loads of existing forging presses are compared
with each other in order to gain a basis for the layout, it wiU be noticed
that the return loads take about 5 to 6% of the press load for moving
crosshead-type presses with steam- or air-hydraulic operation and about
8 to 10% with accumulator operation. The higher value for accumulator
operation results from the larger press plunger are a due to decreased
operat ing pressure - usually 3,000 to 4,500 psi. as compared with
6,000 to 7,000 psi. for steam- or air-hydraulic operation - and conse-
quently the increased plunger weight and the larger counter-force of the
prefill pressure.
The weight of the moving parts is considerably larger for the puU
down-type presses; as known from experience, it may reach two to three
times the weight of the push-down-type press of the same capacity.
Therefore, the return loads must be larger by at least the amount of the
increased weight.
On moving crosshead-type presses the return cylinders back against
either the cylinder platen or the bottom platen, on moving frame-type
presses against the stationary platen. They are arranged at the narrow
press side to avoid interference with crane operation. If the return cylin-
ders back against the bottom platen, they are arranged so as to facilitate
accessibility of the die from the narrow side of the press. Therefore, they
are generally placed diagonally and are, moreover, protected by the
columns against heat radiation.
The pullback design depends largely on the operating medium. There
are two different designs for hydraulic return cylinders, which mount on
the cylinder platen, namely cylinders for differential pistons and for
plunger pistons. The differential pistons act on the moving platen directly.
The simple plungers, on the other hand, act upward against the return
crossheads which are connected to the moving crosshead by tie rods
(fig. 54). This design is most commonly used and has the advantage that
only one stuffing box is required for each ram, and the return rods can
easily yield in case the moving crosshead should tilt.
64 FORGING PRESSES
For return devices, which mount on the base platen or the stationary
platen, simple plungers without diverting linkage may be used. In this
case the plungers push from underneath against the moving platen (figs. 8
and 46) .
'F ig. G4. Accull1lllator-opcrated 550-ton forging jlress witlt preftJl vessel mounteu on top, stationary liie
plate, aud plunger-t)"pe ]lullhacks. (TI)': Hydraulik, Duislll.rg,)
The hydraulic return cylinders are made of forged steel (AI SI 1035)
or cast steel (ASTM A-27 GR 60-30). For calculation and design, the
values given in chapter "Press Cylinders" may be used, considering
however, that the internal pressure in the return cylinder may in crease
by the multiple amount of its nominal pressure in case of sudden stopp-
ing of the down-moving press ram or in case of a "break-through" of thc
FORGING PRESSES OF iVlOVING-CROSSHEAD DESIGN 65
ram -- after piercing, when the plug of metal comes free. Aiso return
rods, return crossheads etc. must meet this load condition.
The return rams, like the press ram, are made of hard steel. If the
appertaining cylinders are inserted into the base platen, consideration
should be given to easy dismantling. The return crossheads are either
forged or cast. The nominal stress in the root of threads for the rod"
made of AISI 1035 should not exceed 8,500 psi.
Hydraulic return devices on forging presses, which are to perform
piercing operations in a closed die, are applied with 1.5 to 2 times the
operating water pressure in view of the great pierce resistance at the
beginning of retraction during the first 4 to 8 in. of the return stroke. A
hydraulic pressure intensifier is commonly used to produce this increased
pressure.
Return cylinders for steam- or air operation are generally carried out
only for small and medium size forging presses, that is for capacities up
to 3,300 tons. For presses exceeding this capacity, hydraulic return
cylinders are preferred; for the required pressure water a power water
station is installed, to which also the cylinders for the die shifting table
and the ejecting device may be connected.
Besides the more suitable cylinder design, the use of pressure water
instead of steam or air entails a considerable decrease of the operating
cost. The basic reason for the uneconomics of steam or air operation is the
fact that the pullback rams in hardly any case return to their end position
after the forging stroke has been completed, and the remaining cylinder
space must always be filled again. Therefore, the steam- or air-operated
return devices require, on an average, 20 to 25% of the total energy
consumption of forging presses, while their load component is only 5
to 6% of the press capacity.
The steam- and air retum cylinders and their rams are made of cast
iron (ASTM A-48 class 35). Calculations and design are based on ex-
periences gained from steam engines 1 ). The cylinders are well insulated
against heat losses. The pistons are hollow-cast and provided with three
to four self-tightening rings. As the moving crosshead may slightly
tilt during eccentric forging - due to wear of the guide bushings - the
connection to the piston rod must be capable of yielding.
Forging presses exceeding 3,300 tons, with hydraulic return devices
and large moving weights, are frequently provided with two balancing
cylinders in addition to the two return cylinders; these balancing
cylinders are subjected to constant pressure of the power water station
(fig. 46). Due to the constant lifting force of the balancing rams, most
1) DUBBELS Taschenbuch fiir den Maschinenbau, 12. Aufl., 2. ber. Neudr., Berlin!
HeidelbergjNew York: Springer 1966, and G. BAUER: Berechnung und Konstruktion
der Schiffsmaschinen und -kessel, 3. Aufl., Miinchen/Berlin: Oldenbourg 1910.
[5 :Mtiller, Hydralllic ]!'orging Prp~ses
66 FORGING PRESSES
weights are balanced and the water consumption of the pullbacks is

decreased. By the same amount, however, the weights which take part
in the lowering speed, are reduced. The decrease of the return load by
providing balancing cylinders can be strongly recommended for steam-
or air-hydraulically operated forging presses \vith their own power water
8tation for the return device, as the pump capacity can be reduced
corresponding to the balanced weight.
The design is relatively simple, if the return- and balancing cylinders
are arranged very close to each other and if the rams, which are placed
diagonally, act on the same crossbeam where the lateral return rods are
mounted, which connect to the moving crosshead. For regulating the
lowering speed, the return water of the pullbacks is throttled.
b) Forging Presses of Pull-down Design

Forging presses with the main cylinder arranged under floor, and a
moving frame which moves the upper tools in direction of the stationary
platen, are used if a low headroom or narrow width of the top platen
are of great importance.
Forging presses of the moving-frame design are particularly suitable
for oiI operation, as the arrangement of oiI pumps, piping, and gauges
below floor decreases fire hazards and contamination caused by leak oiI.
The possibility to guide the moving columns over agreat length increases
the stability of the press when forging eccentrically and also 8ettles
objections to the two-column design. The low headroom and the simpli-
city of the press parts within the range of vision, as well as the elimi-
nation of piping above floor are compared, however, with the large
machine depth with elaborate foundation and pit constructions, which
have sometimes to be protected against ground water. Erection and
dismantling work under floor is usually difficult and requires in most
cases additional auxiliary equipment.
The moved masses of a moving-frame press are in most cases 2.5 to :~
times higher as compared with a moving crosshead press of same size.
Balancing of weights by means of corresponding balancing cylinders iR
possible, the influence of the masses, however, when hitting the work-
piece with the die at idle speed cannot be eliminated, and this fact must
be taken into consideration when designing the base platen and thc
foundation. Taking a 2,200-ton press, for instance, where the weight
of the moved masses i8 about 265,000 lbs., amI which move at an idle
speed of 1 ft./sec., the kinetic energy transmitted to the foundation it<
G v2 265,000· 12
E = . 2g- =2-.32:16 = 4,120 ft.-IbR.
On account of the elongation of the top platen of a moving-franw
press due to heat-up, the original parallelism of the columns is lost during
FORGING PRESSES OF PULL-DOWN DESIGN 67
operation, which may entail jamming and heavy wear of the guide
bushings.
Fig. 55 shows a two-column press of the moving-frame design with
Vig, iiii, Water-operaterl l,100-ton two-column forging press of moving·frame design with offsct
colll1nns and t.able shiftablc to cither ,ide, CBy: Sack, Diissrhlorf.)
68 FORGING PRESSES
offset columns and narrow top platen. The press rests an its foundation
with the far-reaching brackets of the stationary platen. The two columns
are guided in long bushings inserted into the stationary platen. Top aml
I
:Fig. 56. 2,000j950-tOll two-COlllllltl forging preso of /llovitlg-frame design for ([irert tiri"" II)" oii
Imnl})S, with six-part tnol carrier. (By: J.Jukc Brie, Buffalo.)
J<'ORGING PRESSES OF PULL-DOWN DESIGN 69
bottom platens are each connected to the column ends by a diverting

linkage, in order to eliminate the counter nuts. By slightly lowering and
turning the die, a quick change of the die way direction is possible.
Accordingly, a locking device for longitudinal and lateral directions of
the lower die has been provided which is not shown. The die slide table
is movable to either side. Cover plates attached to the table prevent
damage and contamination of the shifting device. The press is operated
by water, which is fed into the movable main cylinder through the ram
mounted to the stationary platen.
An oil-operated two-column press of the pull-down type for 2,000/
950-ton capacities is shown in fig. 56. The columns are guided in sleeves
of about 10 ft. long and are firmly connected with their ends between
the outer and inner nuts to top and bottom platens. The bottom platen
accomodates three inserted cylinders, where the middle cylinder may,
at option, be made run idle in order to decrease the capacity and increase
the speed. Pullbacks between the stationary and the top platens are
safely arranged behind the columns. The location of the columns is
chosen as to provide lateral shifting of the lower tools. For this purpose,
six tool carriers connected to each other are provided, which travel on
rails - with four wheels each - outside the press while they slide on the
press frame and can be locked in working position. Shifting is effected by
a variable-speed oiI motor with reduction gear over rack and pinion
mounted at the bottom side of the tool carrier.
A frontally located track-bound manipulator and a crane mani-
pulator, which can operate at either press side, work at the press. The
press drive consists of twenty constant-delivery axial piston pumps with
a total delivery of 700 gpm. at 2,000 H.P. maximum hydraulic out-
put; they are located in the upper part of the two-floor celIar and driven
by 10 motors of together 1,500 H.P. continuous output. According to
the manufacturer, with 2,000-ton press load, 30 strokes per minute of
4 in. at 1 in. penetration depth can be performed. The operating speed
of the press at 2,000-ton press load is approx. 3 in./sec.
The oil-operated four-column press of the moving-frame type as per
fig. 57 with 900-ton capacity has two cylinders between the columns.
which mount on the stationary platen. The ram loads are transmitted
into the lower platen through pressure rods, thus relieving the ram
guides from lateral forces due to heat elongation and eccentric forging.
The columns are surrounded by spacer jackets which are inserted into the
top and bottom platens and guided in bushings; they are pre-tensioned
over the whole length. The center part of the top platen is narrowed to
provide good crane accessibility. The central return cylinder is mounted
to the lower platen and moves over a ram that is connected to the station-
ary platen by rods and crossbeam. The stationary platen has a guide
70 FORGTNG PRESSES
for the unilaterally shiftable table driven by a differential piston. The

press rests with the consoles of the stationary platen on adjustable
wedge-type plates. For automatical actuation of the control gears, a
traveling rack engages a shifting gear mounted to the stabonary platcn.
Fig. Si. Oil-opel'atet..! 900-ton four-column forging Pl'C:;:-' of llIoving-fraJllc dt':,-ign and two-c ylillclf'J'
construction witl! iackcted (·OIUllIllS. (Ry: ~;\llllllCO, T,evcrkusPll.)
Additional linkage and stop plates are provided for the end positio!1s
of the stroke.
The drive of the press, which is located in the lower part of thc two-
fioor cellar, consists of three double-acting pumps of the five-piston-
series design with a total delivery of 325 gpm. for a maximum pressure
of 4,500 psi. The working speed of the press is, therefore, approx.
3 1 / 8 in. /sec.
The design of one of the largest pull-down presses built so far, with
a capacity of 2,750 tons as per fig. 58, eliminates positively the dangerous
];'ORGING PRESSES OF PULL-DOWN DESIGN 71
I
l~=r:·-r·t-=-.-.=!,. ..--;:.-•.1.d
--1f;?
Fig. ~8. 2,i50-ton four-rolumn forging pres, of 1l1oving-frame design and two-e)'lindl'r eon,truetion
with central guide stalk. (By: Rydraulik, Duisburg.)
72 FORGING PRESSES
bending moments in the columns as well as the drawbacb caused by

heating-up of the top platen. For this purpose, a centrally arranged guidc
shaft is provided to take up the moment resulting from eccentric forging,
Ieaving the columns to take only ten sion forces. The danger of column
cracks, which cause has mainly been the bending stresses, is, therefore.
almost completely eliminated. Due to the largc diameter of thc guide
shaft, which lies outside the heat range, the bearing pressure in the
guide bushings and thus the wear are extremely low.
The guide bushings in forging presses of moving-frame design, the
columns of which are commonly guided in long lugs exclusively, show a
great wear due to the unavoidable heat elongation of the top platen. The
columns of the press with guide shaft as per fig. 58 have ample clearanec
in the guide bushings and back against these bushings only aHer platen
elongation has taken place.
The four-column press is provided with two cylinders inserted into
the stationary platen, the rams of which act against the lower platen
through spherically machined thrust plates. The diagonaIly placed push-
backs are also flexibly arranged between stationary and top platens.
The top platen, narrowed-down in its center part, allows for close cranp
operation. The die slide table for the lower die may be shifted by meam;
of a differential piston 80 in. to one side and 20 in. to the other side
against a stop plate and ean be hydraulically interlocked in the variau;;
positions.
The forging press may be operated either with water or oiI.
c) Forging Presses of Single-Frame Design

Forging presses of single-frame construction are mainly used up to
.'550 tons capacity and in some cases for loads up to 1,300 tons (figs. 59
to 61). Their advantage as compared with same capacity column presses
is the overall accessibility of the forging dies, thus faciIitating handling
of the workpiece as well as changing of the forging directions when
planishing. For this reason, the axes of the dies are frequently located
at a 45° angle relative to the frame axis.
The disadvantage of the single-frame presses is the heavy and expen-
sive construction due to unilateralloading. Therefore, presses exceeding
550 tons capacity are preferably built again in the column construction,
where the ingots can only be forged in the direction of the narrow die side.
The press frame is made of cast steel (ASTM A-27 GR 60-30) and is
simultaneously stressed in tension and bending in its critical cross-
section, that is at the point furthest away from press center. An exact
determination of the bending stresses - with regard to the difference of
frame cross-sections - is complicated; therefore, the approximatc
combined tension and compression stre;;s at the point of slight Cl1rvature
FORGING PRESSES OF SINGLE-FRAlVlE DESIGN 73
:Fig. 59. Ail'-hYllraulic single

frame 1,820-ton forging
lH'eS:$ with split framc aflll
inte~rally caRt prefill vc"sel.
(Br: Enllltlco, Levrrknsf'Il.)
is roughly calculated by the equation

P Plc
S = A ± 1
Key:--
P = press Ioad in lbs"
A = frame cross-section in sq. in.,
l= distance between cylinder axis and center of gravity of frame in in.,
c= distance from the outer tension and compression fiber to center of gravity
in in.,
1 = moment of inertia of the cross-sectional area in in. 4 •
74 FORGING PHESSES
The cross-section is chosen big enough as to not cxceed a nominal

bending stress of 5,500 to 7,000 psi.; the distinctly noticeable elongation
Fig. 60. Shop aSSf'lllhly of forging prrss as 1)('r fig, 59,
during forging, the so-called "breathing", is thus maintained within

bearable limits.
When forging eccentrically, an additional bending moment occurs in
the frame cross-section perpendicular to the afore-mentioned bending
moment; it is advisable, therefore, to make the frame a box-type casting,
in order to attain in any direction a section modulus which is as great
as possible. The additional stress has already been taken into account
in the permissible values given.
It is advantageous on big singIe-frame presses (fig. 59) to abandon
the frame shape and convert it to a lever system. The pivot point is
FORGING PRESSES OF SINGLE-FRAME DESIGN 75
carried out as a common bearing for both cast steel halves , which are
pre-stressed by shrink anchors in the frame breast. The shrink anchors are
Seclian A -O L.o
B_i
)50o- - --
-------- 7~60 -----
- - -- 8000- - - - -
'
$O'~ .
, .
~ -
Seclion C-p
Fi g. (lI. Oren-Iram" 'iOO-ton f'orging vre" for accumula t or overation with B,OOO psi. ope rating ",atrr
]Jres8urc. (H y : Emuueo, T~cvcrkuse n.)
necked-down bolts; the pre-tension in the shank is allowed to be 60°j.)

of the yield strength; the anchors are , therefore, subject to only low
repetitive stress during operation.
The main cylinder of single-frame forging presses is usually inserted
into the upper frame half; in few cases only it is flanged to the framc
face and secured by bolts or shrink rings. Moreover, as a rule , cylinders
and frames are not made a one-piece casting, as the casting may easily
become waste by core displacement in the cylinder or shrink holes.
76 PRESSURE FLUID INSTALLATIONS
For designing the press cylinder, consideration should he given to the

notes on p. 38 et seq. The ram head is provided with a cylindrical or
angular-shaped guide which is mounted to the frame, its size depends
on the dimensions of the upper tools and sometimes also on the ram
diameter. The guide plates are exchangeable and made of cast iron. The
daylight dimension above the lower working table must permit the
removal of the ram, otherwise the guide has to be removed or, in
case of a two-piece guide, its cover plate has to be separated from the
frame. The notes given on p.63 et seq. should be observed for the
construction of the return device.
In order to obviate leaky pipe connections at the cylinder, caused
by "breathing" of the frame which could be 0 .2 in. and more in the
center of the ram at fuIl press load, depending on the press size, the
hydraulic lines are flexibly arranged in the form of a bow or a trumpet
(fig. 60). Proven dimensions for open-frame presses are given in table 8.
Table 8. Main Dimensions of Single-Frame Forgin[J Presscs
DayUgllt I Dic
I o",","
.'re ' t.rok
I 'rabi 1ngo
O>
('ll l)acity Thr nt e Table r . • cction ,' ide J3cari Il~

to to Ra lll ". Ilr es urc
ratio
Guide h ud l'
P li lx w ,viI p-
ZX la
tOIlS in. in. În . in, I in . in . ]J.i.
14 28 36 3 6 X 6 9 11zx 33/ \ 7,4.~O

16 30 3 40 '1 X 1>/ 13 X 43/ 7, 50
1 32 40 45 11 x ll 15s/4 x 531 7,950
20 :~4 46 52 13 x 13 1 X 6 ,000
22 36 52 59 15 x 15 20 3/. x 7 7,750
24 3 56 64 163/. x I6 3/. 22 1/ 2 X 7 1/ 2 about 7,850
26 40 60 69 19 3 / " x 193 /. 26 X 3/. 1:3 7, 5
2 44- 66 76 21'/2x 211 /z 29 1/ zx l0 7,600
30 4 70 3 23 3/. x 23 3/ . 321/ZX 103/'1 7,5 O
Chapter II
PRESSURE FLUID INSTALLATIONS FOR

FORGING PRESSES
a) Pumps
The starting point for determining the size of pump for direct drive
of the forging press (see fig. 6) are the greatest working speed v required
during the actual working stroke and the press plunger are a A, which
accrue the pressure fluid consumption Qmax = A·v of the press, equalling
the required pump delivery, if leak losses are neglected. The compressi-
PUMPS 77
bility of the fluid and the vessel- and column elongations do not affect
the amount of fluid to be delivered during the working stroke.
The required output at the crankshaft of the pump for a drive
without flywheel is derived from the equation
H P = .. _P.Y. __ or H P = Qmax v
.. 550 tIn 1]", •. 550 TI" 1]",
Key:-
P = A·p = nominal press capacity in Ih8.,
v = working speed in ft.!sec.,
Qmax = pump delivery in gpm. for the working speed v,
p = fluid pressure in the press cylinder in psi.,
1]" = the volumetric losses in the pump and leak losses,
1]", = the friction losses in the pump and the flow losses up to the press.
For rough estimates, rin is substituted by 0.94 and rJm by 0.85, thut;
obtaining the simple formula for the motor output, without considering
rotating masses: -
HP Pv HP _ Qmaxp .
. . =440 or .. - 440
If a separate small accumulator is employed for the returns and for

driving the auxiliary cylinders, then additional motor output is needed.
In order to get an impression of the sizes, it may, e.g., be referred to
a 1,000 metric tons (2,204,6001bs.) capacity press as per table 14 (p.122)
for comparison. For this accumulator operated press with 40 strokes per
minute and 2 in. penetration depth a pump output of 690 H.P. was
calculated, while the same press with direct pump drive and an assumed
working speed of 100 mmjsec. (0.328 ft.jsec.) would require a motor
output of
H P =~v = 2,204,600' 0,328 = 1 642 H P
.. 440 440 , ..
For this reason, a working speed of v ~ 2 in.jsec. is most commonly

chosen, if the direct drive with pressure water pumps is concerned, which
stiH meets many requirements, but which is slow - as compared with
the accumulator operation entailing small numbers of press strokes.
Fast-running pressure oiI pumps may more suitably be employed,
the upper economical limit for the direct drive of forging presses being
considerably higher as compared with pressure water pumps, due to low
initial cost and little space requirements. A size comparison between
oil and water pumps of same output is illustrated in fig. 62. On the other
hand, however, oil installations require more maintenance (see "Pressure
Fluids"), and for this reason sometimes objections are raised in forgc
shops against the introduction of the oiI drive.
Centrifugal pumps are not employed for the direct drive of forging
presses due to the changing operating pressure.
For the direct pump drive piston-type pumps are employed exclusi-
vely, which run continuously and are changed over to "by-pass" aHer
the end of the press working stroke.
For pumps with constant delivery, different working speeds may be
achieved by partial by-passing of the medium with the hclp of a regu-
- - - --.-- -- -- - 6150 - -- - ---
~ -·-·- @l--·
1
~
~K '--~-'----r----' &1
j
!
I
fi b
I
-+-. I
1
1\'jg.62. Comparison of space rcquiTcd by pressure water pll1np (a) and pr(>~sure oilpuJIl}J (1)) ofeqllal
ontpnt of aJlprox. 5:30 g. p.m. H.t a,uon psi.
lating valve OI' by splitting Up the total pump output on several pumps,
which may, depending on requirements, be switched on OI' off. Moreover,
pump sets with individual drives offer the advantage that one pump can
be repaired without any major shutdown.
Piston pumps are mostly built with single-acting plunger pistons.
AIso , double-acting units are known with either a differential piston or
two opposite pistons with divert.ing linkage , driven by one crankshaft.
1. Water-Hydraulic Pressurc Pumps

There are two types of water-hydraulic pumps to be distinguished -
the vertical and the horizontal pressure pump . The vertical type requires
less space than the horizontal one and - fitted with overhead crank-
PU:lTPS 79
shaft - it is especially suitable for direct Bat or V-belt drive with a

maximum capacity up to about 150 H.P. In general practice, however,
separate gear drives mounted in a housing are preferred to the belt-
drives, although the initial cost of a gear drive is higher; they are difficult
to connect ta the high crankshaft, and nawadays vertical pumps are,
I
i
-f
I
i
]1'ig. G:.t Triplf'x watcT-hy(lraulic pr{'~':'mff'>' IJump with sevarate PUTI1P housings alHI ~uperj:1(':{,llt ~nc
tiOH- aud dischurge valves. Capacity approx. 275 H.P. (By: Sehloemann, Diisseldorf.)
therefore, seldom used. If, however, the crankshaft of a vertical pump

was arranged in the bottom - as in a vertical steam- or Diesel engine -
and the working cylinder in the top, the stuffing boxes for the plunger:-;
would be over the crankshaft, permitting water to leak into 1.he 10wcl'
}'jg. 64-. Shop pllOto of a watcr-hydraulir. l-lrcs~urc lJUlUP as ]H'T fig. 6:3.
part of the crank case and mix there with the lubrication oiI for thp
bearings.
The horizontal water pumps are almost exclusively built with thrce
plungers (figs. 63 and 65), without considering the small sizes. For two
coupled triplex pumps the nonuniformity of water delivery may be
decreased from 14% to about 3.5% by displacing the crankshafts at a
30° angle.
The dclivery curve of piston pumps with crank- or cccentric drive
shows a nonuniformity depending upon the number of pistons. If Qo
indicates the maximum pumping capacity, Qu the minimum pumping
capacity of the composed delivery curve of aH pistons at constant rota-
tion speed and Qm the medium pumping capacity of the delivery curvP.
then the coefficient of uniformity is u = Qo,~ib . X 100 in %.
~m
The coefficients of uniformity of single-acting plunger piston pumps

are tabulated in table 9 and shown in fig. 67 for different numbers of
pistons, under the simplified assumption of a crank-of-breech ratio of
PUMPS 81
1
- = 00 (1 = length of driving rod, r = radius of crank). Principally, the
r
nonuniformity decreases with increasing number of pistons. This is
true for pumps with an even number of pistons only, if by the arrange-
ment of unequal crank angles a decrease of the nonuniformity is possible.
:Fig. 65. Triplex watcr-hydraulic pressure pump with separate pump housiugs aud series-arraugrd
suetion- aud discharge valves. Cavacity 270 H.P. (By: Hydraulik, Duisburg.)
]'ig. 66. Shop assembly of the water-hydraulic pressure pump as per fig. 65.
This, for instance, does not apply in case of the quartuplex and octuplex
pumps; therefore, the triplex pumps deliver considerably more uni-
formly than the quartuplex pumps (see fig. 67). The fast-running multi-
plex pumps, mainly used for oiI operation, usually operate with seven
pistons, but other odd numbers of pistons between 5 and 15 are
also used. The larger the number of pistons, the more sensitive the
delivery curve is against unfavorable influences, such as one leaky piston
or valve, thus superimposing fluctuations on the rhythm of pump rota-
tion in the delivery curve, which results in a considerable increase of the
6 Mii ller, Hydrflulic l~'orging IJrrss('s
82 PRESS(;HE FLCID I",STALLATIONS
r~ coefficicnt of nonuni-
c:.:
formity. This cffeet,
~c::..:
..... however, is (Jnly of im-
portanee for presseR,
where an even motion
"" of the press ram 18
r~
rcquired 1).
~c::..:"".... The eomponents of
a water pump are:
<:;,
Base frame with
crankshaft bearing and
r~ crosshead guide, crank-
<f! c:.: shaft, driving rods and
c:.:
~'-<> crossheads, pump pi8-
tons, pump housing,
valves, and variom;
""
W gauges.
'" The base frame iR
aE!
8
~ l<~
<>.: made of cast iron (ASTM
.....
. A-48 Class 20). It should
11 ::l
- 1
be fairly heavy for
~.,
~
"" pumps with high ro-
l>l
.:
~"- o '" tation speed, in oreler to
~
"'-: avoid any noticeablp
.~ ....,
11;
~"'-:
vibrations hy the 08-
~
,:, eillating and rotating
~ ~ IO masses. A frame of a
';:
- ::; wide U-shaped vertical
'"
'.
." pump eross-section (figs .
E
63 and 65) i8 simul-
- ~ taneously stressed for
'O 'O
." hending and tension .
1:"
~
;;
-
.;;
o:::
The eomposed nominal
'-
'.
'"o stress i8 maintained be-
"'" W
tween 1,000 and 1,150
-:;
::>
,..: lbs.jsq. in.
"",,;, The crankshaft bear-
:;
ings are either of two-
pieee or four-pieec elP-
1) See E. MtiLLER: HydrauJische l'rcssen Hud Dnwkfiiissigkeitsaulagen, Bd.:3.

l'ressen fiiI' die Herstelluug von Rohreu, voll- nud hohlprofiliert.en Stangen,
Drăhten sm\ie Kabelmiinteln an~ NE-::Uetallen, Berlin/Guttingen/Heidelberg:
Springer HJ3H.
PUMPS 83
Table 9. Delivery and Coefficient of Uniforrnity u of Piston Purnps
~ - Angle' )
'-
o
...
' pper I Lowe r
...'"
:> Averugc
,Ic lh'cr~'
1 co"meÎent of
uniformity
I
~ rrOIll crnnk Iî mit of d eli\'cry
.: ;!;
t crn nk ~
:= ~ Clln"
c- ll elllnrk s
I
~ ~ .§ Qm = ~ Q D1fU-: . = Q.- Q. ·100
= ~.
" I
U
Qm
z "
.~
'"
~:. ~
Q. Qu,
"<
§
Q It gplll.' ) ",Pili, ') I ~ gpm . ')
°'0
11 1 a60 1 1 O 100 I 0.aI8:~ 314
-- - ----- -
'l
2 180x 2 2 ] O 100 0.6366 157
- - - - -- - - -- - - - -
3 3 120 x 3 6 1 O. 66 13.4 0.9549 14.03
- ----~
4 4 90 x 4 4 1.4142 1 41.42 1.2732 32.53

-- -- -- - -- -
5 5 72x 5 10 1.618 1.5389 7.91 1.5915 4.97
-- ---- ---
G 6 60 x 6 6 2 1.732 26.8 1.9099 14.03 Hke 3.})i. ton
pump
I
,
7 6 30,90,30, 12 1.9318 1.866 6.58 1.9099 3.45 two 3-pi tot
90,30,90 pump displaced
I
------ I by a 30° angle
7 5P/, x 7 14 2.247 2.1906 5.64 2.2282

I 2.53
- ---
I
8 45 x 8 -, 2.6131 2.4142 -1 19.89 2.5465 7.81
I ---- --
10
Il
9
O 36 x lO
40 x 9 18
10
---
2.8794 2.8357
3 . 236 3.077
4.373
15.82
2.8648
3.1831
-:1- 1..'53
4.97 like 5·pi ton

1
pump
12 10 1 ,54,18, 20 3.1962 3.1:369 3.93 3.1831 1.236 two 5-piston

54 etc. pumps displaced
I byan 18 0 angle
l a Il 328/u x n 22 3.5133 3.4776 3.577 3. 5014 1.022
14 12 30 x ]2 12 3.8636 3.732 13.16 3.8197 3.45 Jike 6-piston

pump displaced
(a per l'unning
number 7)
1.'5 12 45,30,15, 24 3.8306 3.7979 3.27 3.8197 0.857 two (j.piston

30,45,30, pump (as p er
15, 30, running number
etc. 7) displaced by il,
45° angle
1) Not determin ing for the piston sequence.

2) The figures apply. if Qn"" of the single piston is deslgnated by } gpm. at
the point of 1'",,,,.
6*
sign. Bearings exceeding 8 in. in diameter and having automatic lubri-

cation are designed from experience and calculations for piston engines ;
these represent also the basis for the design of the other crank gear com-
ponents.
The crosshead guides at the base frame are either cylindrical 01' ftat.
Both guides are provided with bushings 01' wear plates of cast iron.
The crankshaft is mostly made of open.hearth steel (AISI 1035).
The permissible composed nominal stresses of bending and torque are
5,700 to 7,200 psi. The crankshaft is provided with either duplex OI'
quadruple bearings. The duplex bearing offers the advantage of a narrow
base frame width and makes a one-piece construction of the pump
housing possible. A quadruple seated crankshaft (figs. 63 and 65) is
additionally supported between the cranks and may, therefore, be
weaker in design. Due to the increased base frame width, the pump
housing must be of a three.piece construction. The design is chiefty
applied for double-acting pumps, where the puU rods for the pistons,
located at the real' end, are arranged at the sides of the pump housings.
The Marine Engine Specifications 1 ) offer good comparison values for
dimensioning crankshafts with intermediate bearings.
The bearing pressure for crankshaft pins should not exceed 285 to
430 psi. In order to dissipate the heat from the shaft pivot, the lubri-
cation oil must be cooled.
The driving rods and crossheads are made of forged steel (AISI 1035)
OI' cast steel (ASTM A-148 GR 80-40). The buckling stress in the rods
is calculated with a commonly used safety factor of 10. The crank-of-
breech ratio is usually llr = 5. The permissible maximum bearing
pressure for the crosshead pin is 1,300 psi., for the crank pin 860 to
1,000 psi. The crosshead shoes are usually adjustable by means of
shims. The permissible pressure on the sliding surface is 30 to 50 psi.
The eylindrieal erossheads are frequently provided without adjustablc
means, and the cast iron guide bushings are rather replaced if they are
worn. The pin conneetion for the driving rods in a erosshead with eylin-
drieal guiding is frequently replaeed by a spherieal seating on bronze
plates.
The pump plungers should have a hard and smooth surface; they arc
made of nitrated 01' ftame-hardened steel OI' of alloyed stainless stecl.
The medium piston velocity is ehosen vm;;:;; 10 ft./sec. The plunger-
crosshead eonnection must be either ftexible in vertical direction with
regard to the plunger axis 01' adjustable in order to obviate leaky
packings, if the crosshead guides wear.
1) BAUER, G.: Berechnung und Konstruktion der Schiffsmuschinen, Munchenj

Berlin: Oldenbourg 1908.
PUMPS 85
Sleeves of leather 01' vulcanized fabric are used for the stuffing box.
The sleeves are particularly suitable, due to their short length, for high-
speed pumps with short stroke; a medium plunger velocity of Vm =
3 ft.1
sec. should be aimed at for
preventing excessive packing
wear. Lip packings are em-
ployed for large plunger
diameters (see fig. 68). Di-
mensions for packings and
stuffing boxes are given in
table 6, p. 50.
In general, the piston
stroke should be longer than
the packing to ensure moist-
ening of the packing material Fig. 68. Sealing of a pnmp piston by vuleanized packing.
by the pressure water. (By: Merkel, Hamburg.)
Vulcanized textile-fabric
packings feature particularly long service life. Uninterrupted 12-months
operation has been observed.
If possible, the liner length is made l = 1.5 to 2 d, d being the piston
diameter. T he packing gland con i ts of either
an adj u ta,ble ftange or a screwed connection .
Only a special grease should be u ed for lubri-
catio n of t he packing .
'Fig. 69. P " mp housin!! wilh , upcrjaccnt uel ion· unu di schargc
\'a h·es. (13y: &hloc ]])"I1I1, Dti ...·cluorf.)
The pump housing is of forged open-hearth steel (AISI 1035). The

channels and valve chambers are bored out. The suction- aud discharge
86 PRESSL'HE FLUID INST,\LLATIO);S
valves are arranged either side by side or supcrjaccnt. Valvcs, valve seat".
and screwed components are made of high-duty bronze. The val\"('
springs are made of either the same material or of Rtainle:-;:-; stcel. The
medium fiow velocity in the suction valve should bc r, = 10 ft..'sec.
and in the discharge valve Vd = 20 it.fsec, For computing the valvc flo\\'
Yh!. il. Twu-;.;ta,ge POI)pct yalvc for tl\(' suetiull- ;\]\(l

(li"chargt' cllalllhcr:-:.
area, a valve stroke of about li S to "/16 in. ii:) figured. In order to obtaill a
large free fiow area, the suction valves are carried out as ring valve".
whereas the discharge valves arc usually made simple poppet valves. 1'he
seats of the suction- and discharge valves are frequently leather-packccl
to obtain a better seal. Very large valves are in mauy cases replaccd by
two discharge- and four suction valves, alI being of thc same size.
When designing a pump housiug, care should be taken above alI that
no aiI' pockets can form and that any sucked air can escape again froJll
PUlVIPS
Table 10. Standard Dirnensions for PUIllPS

(Extract from DIN 2770; with alI dimensions converted into English)
Power Requirements, Motor Capacity, Nominal Pressures, Deliveries
. Po wc r I·C. llIir c ~ )lo milla l p r~ - '"re I',i .
"le ll t al th e :-Iotor
era llk"h'lfl r'a pac it)" 2,:\00 :1,000 :1,;;00 4,500 6,OOll
H ,I' , k II' 1 IÎ\- -· r~· in 1! PIll ,
62 5 i)9 :37 ao 24 J9 lii

785 0:.1 74 45 :~7 30 24 19
100 O 94 59 -1:8 :31 :10 24
125 10 119 74- 59 48 :37 ao
157 ][25 148 94 74- 5~) 48 37
203 1 O 1 7 ])9 r)4 74 59 4
250 200 238 14 U9 94 74- -9
:3 15 250 296 1 7 ]48 lIH 94 74
400 315 370 2:38
1 7 14 119 94
fOO 400 476 296
23 1 7 148 119
630 500 590 296
370 2a~ ] 7 14
790 630 740 47fi 370 296 238 187
] ,020 00 610 476 34-,') 296 2a8
1,260 J ,000 770 OLO 47G 345 296
1,(i00 1,250 94- 740 610 476 345
2,050 1,600 1.190 940 I 794- 610 476
Static Piston Loads, Piston Diameters
S O"' ;":1 1 Il I'CS,"rc p. L
Stal k
.. i. lo li loael') I ,;,OU 2,:)00 :I ,OOU 3,5UO G,OOO
H,,, _ Ph.tult d ia mctcr inellc''i)
2,200 1.42 J .LO 0.9 0.87 0.79 0.71

2,750 1.57 1.26 1.10 0.98 0.87 0.79
:3, -20 1.77 1.42 1.26 \. \ O 0.98 0 .87
4,400 1.97 J .:3 lA2 LZli 1.10 0.98
5,-00 2.22 1. 78 1.58 1.4:2 1.2G l.L0
6,940 2A8 1.97 1.78 ] .5~ 1.42 1.26
8, 00 2. O 2.:22Ul7 1.7 1..5 1.4~
1 \ .000 a. l i) 2.48 2.22 1.97 .1.7 1.58
13, :')0 :\.1>-1: 2.80 2.48 2.22 1.97 1.78
17.600 3.94 3.t5 2.80 2.48 2.22 1.92
22,000 4.4\ :3.54 :U i) 2.80 2.4 2.22
27,500 4.92 3.9! 3.54 3.15 2.80 2.48
35,200 ' 'i.ii \ 4.4 \ :,1.97 3.54- 3.15 2.80
44, 00 6.30 4.92 4.41 3.97 3.54 3.1:3
55,000 ' ).:') L 4.92 4.41 3.97 3.54
69,400 1i.30 5.51 4.92 4.4L :3.97
88,000 7.lO 6.30 5.51 4 .92 4.4l
110,000 7.88 7.1.0 6.30 Fi .51 4.9:2
138,500 8.8:2 7.88 7.10 G.30 5.51
176.000 !). 5 2 7 88
. 7.10 6.30
Rotations per Minute (Under Load)
171 ". 80 I
' 90 i100 '
i 112 " 125 " 140 1160! 1801 200! 2241 2501280 I 3151 :355140U
1 I
Nominal Diameter of Valves (Selection from DIN 2402)
1 3/s I 518 I 3/4 I 1 I P/41 Ilie i 2 '21/2131/41 4 ~ ii i 61 /21 inches
1) Static piston loads: Piston area x nominal pressure (rounded off as per DTNa23).
the pump chamber through the discharge valve. In order to prevent

cavitation of the water columns at the suction side caused by their great
Fig. 72. Triplcx ]lUIllP for the opcration of a 7,700·ton forging press (as per In"titution of McclJallica I
Enginecrs, London, 1946).
speed changes and to ensure smooth operation of the suction valves, an

air vessel is arranged near the pump with short suction lines to the pump.
The medium water velocity in the suction line should not exceed
1 ft.jsec. and the water level of the reservoir should lie approx. 13 to
PUMPS 89
161/ 2 ft. above pump centerline. Very small pumps may also suck the
water from a steel tank arranged underneath.
Fig. 73. Cross·section through vnlve bousing of

llUmp as per Ilg. 72.
Armatures of the pump housing are, besides the suction air vessel, a
spring-Ioaded safety valve, an air vent and a gauge with shutoff cock.
The pump types are distinguished by the plunger force, which varies
- between the smallest and largest pumps - between 2,200 and 44,000 lbs.
The plunger cross-sections are obtained by the plunger for ce and the
operating water pressure. The pump rotations are between 125 and
180 r. p. m., the smaller values applying for the large pumps. The motor
capacity is chosen 10% above the calculated requirements. Standard
pump dimensions are given in table 10.
Figs. 72 to 74 show the design of a triplex pump for the direct ope-
ration of a 7,700-ton forging press 1 ). The deliveryisapprox.l,700 gpm.,
the operating pressure approx. 5,700 psi. and the revolution speed
84 r.p.m. These figures correspond to a short-time output of 6,500 to
7,000 H.P., which are transmitted by a flywheel arranged on the fast-
running gear shaft. The drive motor is designed for a constant capacity
of 2,500 H.P. at 600 r.p.m. and permits a decrease of rotation speed of
max. 15% of the nominal rotation speed. The pump frame is a three-
1) ,J, Tron Steel Inst. 161 (1949) February.

90 PHEsSrltE FLUD I:\ST.\LLATlOXS
Vi;::!. Î -1:\
Vi.!!. 741\
Fig. 7-la alul b. Oyprall yin\" alld lltllllP driyp il:::; I)('r fig. ;~.
PC:VIPS !n
piece unit. The crankshaft bearings have a diameter of 480 mm (19 in.) .
The stroke is 942 mm (37 in.) and the plunger diameter 197 mm (73/ 4 in.).
Proven dimensions of pumps for other forging presses are listed in
table Il.
Table Il. .Main Dimensiol/s for Pumps and Forging Efficiency of Directly Driull
Presses
(.J. Iron Steel Inst. 161 [1949] Febr.)
»UIllI) ~fo' o r
1:
'"
;;: I
E
E
5"
~.
N il }.7
i n.' r .l1.
tOI1 ::3 ~l'C . gpm. m. in. in. H,T'. .H .I'. ' ,. tons tons k W h 1)
] ,600 2 2 4 5,700 1,200 15 87 52 31.2L

1,600 2 284 5 700 1,200 }.') 120 72 21.75
2,500 2 450 5,700 2,000 15 50 32 28.23
2,500 2 450 5,700 2,000 15 100 60 21.06
4,400 2 795 5,700 4,000 15 19 12 34.0
7,.700 2 1,390 5700 6,500 ] 5 320 180 26.7
2. Oil-Hydraulic Pressure Pumps

It is possible without any difficulties to also employ oiI as the trans-
mission medium in the water-hydraulic pumps described in the previous
chapter. With re gard to the special characteristics of the oiI as operat ing
medinm, important components such as piston sealing and control gears
can be made much simpler. The development of oiI pumps, therefOl'p.
was basically different from that of water pumps. Due to the highcl'
viscosity of the oiI and its lubricity it is possible to guide ground pistom;
in the cylinder, with only the necessary clearance for lubrication, without
any particular sealing. The pressure oiI leaking between the moving
parts permits relatively high rubbing speeds and also serves as coolant.
A short piston stroke may be chosen, because there is no danger of dry-
running as would be the case with the lip packings (see p. 49). Thi:5
renders possible a considera bIe increase in motor speed and coupling
of the pumps directly with the motor.
OiI pumps are of multiple-piston design with either axial or radial
arrangement of the pistons or with the pistons arranged in series. Both
axial and radial piston pumps are built for constant as well as infinitely
variable delivery.
1) The difference in power consumption is a result of the various hot stoek

shapes.
92 PRESSURE FLUID INSTALLATlONS
]~'ig. 75. Constallt-delivery pre~~ure oiI PUIJ1P with suction- aud Fig. 76. Sed ion through llUlll]l
disc!lUrge valvcs. (By: Towler, Rodlcy.) ~h()wn in fig. 75.
Fig. 77. Twin ]l1ll1l11; regulat ion of dc1ivcry uy individual control of ]lUJlljlR. (By: Towler, ltodlPy.)
Fig. 78a--c. Sr:l1l'matic diagram of sh·(Jl.;:p variat.ion of il radial pbton pUlllp.

PUMPS 93
Figures 75 to 77 illustrate a five-piston pump arranged in line with

delivery- and intake valves for an operating pressure of 5,700 psi. and
more. The piston housing of the pump is of forged steel. The pistons are
forced into the bores by a constant stroke, over head-arranged eccentric
Fig. 79. Variable·delivery radial piston pump. (By: Kicler Howaldtswerke, Kic!.)
shaft and barrel rings,

and retracted by springs
at intake stroke. The
intake and delivery valves
are easily accessible after
removal of screwed com-
ponents. The bores also
serve as valve seats; there
is no wear as compared
with the water-hydraulic
pressure pumps. The
whole pump is encased in
a closed housing filled
~Fjg. ilO. Sh01> photo of rotor of pump shown in fig. 79.
with oiI.
Large deliveries may be obtained by coupling severai single-, twin-, 01'
multiple pumps, thus also rendering possible a velocity staging of the press.
The principle of the infinitely variable radial piston pump is schemati-
cally illustrated in fig. 78. The radial pump possesses a stationary shaft a,
on which the pump body b, which is directIy driven by an electric motor,
rotates. At each rotation the pistons c move. They run on rollers in an
outer race d. When the centers of the pump body and the l'a ce are in
one axis (see sketch a), the pistons stop in the position shown in the
sketch, i.e. the delivery of the pump is zero. The race being shifted to
n4 PHESSCRE FLrID IKSTALLATTO:,\S
the right (sketch b), the pistons perform a reciprocating motion on each
revolution in the pump body. This motion increases as the l'a ce is shifted.
Thus the delivery of the pumps is variable at random. To enable the oil
to enter the cylinder bores on the intake stroke and to emerge on the
discharge stroke, the stationary shaft a is provided with two ports e,
t
into which four longitudinal bores connect, of which two ~erve for the
inlet and two for the outlet of the oiI. The race being shifted into the
opposite direction towards the left (sketch c), the motion is repeated
with the only difference that intake- and deIivery si de of the cylinder
change and that the ftow of oiI is reversed.
}<'jg. tiI. J{adial piston 11Hmp for thc din'(·t o]wration of th c forgiug pn':-::-: ;\:-> 1)('1' fig. lin.
:Figs. 79 and 80 illustrate a radial pump equipped with 15 pistons

running in a rotating cylinder plate . The plate a is driven by the sha{t, b
through the disc coupling c. On the opposite side the plate moves with
a socket d over a dowel pin e which is provided with thc control ports and
the oiI inlet and outlet bores. The bores are connected into a manifold
with the two connecting pipings. To ensure solid glliding, the pistons
are provided with an enlarged head having an axle f on \vhich are mount-
cd two ro11ers g on both sides of the cylinder plate. The ro11ers lie against
a race h which is supported on a cradle k, l by two plates i and j. This
cradle k, l with the braces m moves in the spIit housing n, thu~ control-
ling the stroke of the pumps. The suction stroke motion is brought about
by the centrifugal force of the pistons and l'oller~ which come to rest
against the race h.
The design of the radial piston pumps, which hav e been used to
operate the forging press as per fig. 176, is illustrated in fig. 81. Thc drive
Pt:MPS 95
shaft 1 is seated in the tapered roller bearings 2, driving the ro tor 3 which
is seated on the stationary control shaft 4 with the two tapered roller
hearings 5. The clearance of the ro tor on the control shaft may be adjusted
oy the nut 6. Seven radially arranged ground pistons 7 are built into the
h c
:F ig. b~a- -c. Yaln_\-rontrolled 1'H,(lial})btolllllIlIlP for con~t(lllt- and variahlc ddiy pry.
(13y: Execntra, Stuttgart.)
rotor, the pistons are equipped with crossheads at their ends which are
seated in guide shoes 8. The cylinder bores rotate around two control
ports in thc shaft 4, which has two bores for the inlet and outlet of the
suction and pressurc oiI. The guide shoes are inserted into two flanges 9
connected with each other; the IaUer ro tate with the tapered roller
bearings 11 in the race 10, which may be shift,ed in the stationary hous-
ing 12 perpendicular to the plane of the paper. The race 10 is thus brought
in an eccentric position with regard to the rotor 3. In doing so, the pump
delivery may be varied at random from zero to maximum. If eccentri-
city is established on the opposite side, the suction- and discharge sides
of the pumps are changed. Shifting of the race 10 is performed by a
servo-motor, which is directly driven by a small gear pump and may be
easily controlled by hand. The pumps deliver approx. 114 gpm. of
pressure oiI of about 2,500 psi.
A radial piston pump with the pistons performing working strokes
directed towards the outside and driven by a common eccentric, is
simply illustrated in fig. 82. The pump may be equipped with 3, 5, 7,
or 9 cylinder units and is built either with single eccentric (fig. 82c) for
constant delivery or with twin-eccentric (figs. 82a and b) for infinitely
varia bIe delivery. The controllability as per fig. 82 a is ensured by rotation
of an outer eccentric C over an inner eccentric a by means of a planetary
gear b, thus the total eccentricity may be determincd as a geometric
sum of the partial eccentricities from zero to maximum. AIso, the reversal
of the oiI stream is possible. Instead of the mechanical adjustability by
means of planetary gear, the pump may also be provided with a hydrau-
lic adjusting device as per fig. 82b, where the relative movemcnts of the
eccentrics are effected by turning a rotating wing d in the ring spaca e
of a housing t which is connected to the inner eccentric a.
The transmis sion fluid for the rotating wing drive is fed and drained
through an axiaHy movable control valve g located in the pump shaft.
The outer eccentric c forces the ground pistons h by means of guide
shoe i and roHer crosshead j at each working stroke towards the outside.
while a spring k effects the return. Suction- and discharge connections are
controlIed bya common valve l, which is positively moved through linkage
n and levers o by a control eccentric m at the pump shaft. The pump is
directly driven through a flexible coupling with a rotation of 1,500 r. p. m.
Operation of the axial piston pumps is effected by a disc the position
of which is inclined with regard to the pump axis. The pistons are guided
at this disc, and their stroke at each revolution corresponds to its in-
clined position. Either the cylinder body or the inclined disc may be
coupled to the drive shaft.
Fig. 83 illustrates one of the various designs of constant-delivery
axial piston pumps. It has a stationary disc e in the pump cover g; the
pistons c with pivoted guide shoes d rest against the disc. The pistons c
move in the cylinder block b which runs in the roHer bearing hand which
is driven by the pump shaft a seated in the baII bearings i. The cylinder
block b transmits the thrust force, generated by the fluid pressure, on
t
to the control disc which is provided with two trumpet-shaped ports
for the suction- and discharge connections.
PUlVIl'S
- e----OiSCha~~ --- -E? b d
-6 .suclilln
l iig. 3. Oil-hydmul ic j)U Jll jl ofaxin l pi"tol1 design wil li !"o n' lant llel h ·cry.
(l\y: 'l'h ~ J)r ni. on EI1I!., 1;0Iu l11l.)II ,{0I1iO. )
:Fig. 84. Variable-dclivery axial piston pllllllJ. (13y: Hydralllik, DllislJllrg.)
7 Miiller, Hy<lraulic Forging l'n"ses

98 PRESSl:RE FLUID INSTALLATIONS
A variable-delivery axial pump is shown in fig. 84. The drive shaft a

is seated in the pump housing in two bearings and has seven cylindcr
bores, arranged parallel to its axis, with pistons b. The pistons sit with
spherical shoes C on a thrust bearing in the cradle d. At each rotation of
the shaft a the pistons b perform an intake- and discharge stroke, the
length of which is dependent on the degree of tilting of the cradle.
The spherical shoes care pres sed against the thrust bearing by a driving
disc e which is spring-seated on the cylinder body. The stationary valve
plate f is provided with two kidney-shaped ports which are connected
to thc cylinder bores and control the intake- and discharge cycle.
In pumps of up to abt. 50 H. P. the cradle dis s,vivelled by hand with
the help of a pivot g; the angular displacement of the pivot is ] 5° to 20°
when the pump performs its longest stroke and the output attains its
maximum value. In the mid-position, stroke and output are zero. When
passing over the mid-position intake- and discharge sides change and thc
flow is reversed.
When human strength is no longer sufficient to adjust the cradle,
a servo-motor with piston valve hand slide valve i is uscel. The servo-
motor is driven by a small gear pump which produees a pilot pressure
of abt. 300 psi. and is rated for 2 to 3 H.P.
When the slide valve i is moved in direction y, its control edges k
open the previously covered bores in the piston valve h, thus enabling
the oiI under the piston valve to pass through bores l and 1n into the
chamber which is connected to the leak oiI circuit and arranged above the
slide valve. The piston valve moves down and shifts the cradle until the
bores in the piston valve are covered again by the control edges. During
this motion the pressure of the oil on the ring-shapeel area of the piston
valve acts as the piston power. 'Vhen the slide valve moves in direction :c,
the pilot oiI passes through groove n and bore o into the annular chamber
and from there through bore l underneath the piston valve h, thus caus-
ing an upward movement which continues until the bores in the piston
valve are eovered again by the control edges k. During this motion the
constant pressure on the ring-shaped are a is overcome by the piston
power. The servo-motor thus acts perfectly as power amplifier.
b) Intensifiers
vVith every stroke the intensifiers create a so-ealled single stroke of
the press (see "Kinds of Drive" and fig. 6). If several single strokes are
required, e.g. for upsetting operations, the single strokes are performcd
consecutively and are called progressing single strokes. Intensifiers may
be compared with a valveless oue-piston pump aud are operated, dcpend-
ing on the form of euergy available, by steam, compressed air, or mechani-
INTENSIFIERS 99
cally. Up to the present, intensifiers have been built only for water
operation and for pressures of 5,700 to 7,200 psi. This pressure may be
applied without objections, as the pressure water, delivered by the
intensifier, is not controlled by valves, and only proper sealing of the
rams must be taken care of. The high pressure offers the advantage of
small ram and cylinder dimensions , permitting a narrow platen design.
The small cross-sectional are a of the ram entails little pullback resistance
and small cross-sectional arcas of piping and prefill val ve.
1. Steam- and Air Intensifiers

Forge shops which have steam or compressed air, stiH use inten-
sifiers today which are designed as singlc-acting, valveless one-plungcr
}<'ig. 85. Stcam-hydraulic 1,GGO-tOll forging prcss with adjacent intensifier. (13y: Banning, Hamm.)
pumps and directly driven by a steam- or compressed air piston, the

stroke of which is controlled by hand. These intensifiers feature simple
design, but are uneconomical with re gard to energy consumption, as they
are always working with fuIl pressure without utilizing the expansion
cnergy. Forging presses equipped with these intensifiers are caIled
steam-hydraulic or air-hydraulic forging presses respectively (see fig. 85.).
7*
100 PHESSURE FLeID INSTALLATlONS
The size of the intensifier depends on the working stroke of the forg-
ing press, the so-called single stroke, which is chosen abt. 8 to 10% of
the total ram stroke (see table 12). The steam OI' aiI' pressurc availabk
is usually 120 to 175 psi. In order to increase the economy, steam and
aiI' are frequently superheated by exhausted fuma ce gases up to 570 to
750 OF. The determining factor for the ratio D:H (D being the diameter
of the steam- or air cylinder and H being the piston stroke) is the medium
piston velocity. It is usually 3 to 5 ft.jsec. The volumetric losses, such
as compression of the water, air pockets in thc water, elongation of
cylinders and piping, and the elongation of the press columns OI' th!:'
frame are taken into account by the volumetric coefficicnt of cfficicncy
of abt. Ii" = 0.9. The mechanical coefficient of efficiency, roughly
iim = 0.95, considers the friction losses in the stuffing boxes and tiI('
flow losses.
There are two different intensifier designs, which arc distinguished by
the upper or the lower arrangement of the hydraulic cylinder. Most of th!:'
steam- 01' air-hydraulic forging press installations ha ve intensifiers with
upper pressure water cylinder. This design is employed exclusivcly for
single-frame presses, if the steam- 01' aiI' cylinder is mounted at the
back of the hame. The advantages of an intensifier with upper pressure
water cylinder are the simple design and the short, direct pipe line to the
press. On the other hand, it might be desirablc - when largc forging
press installations are concemed - to lay the piping from the inten-
sifier in a duct undeI' floor and to emerge with the piping directly at the
press, in ordcr to obviate any obstructions between thc press and the
intensifier, which would render transporta tion difficult. In this case.
an intensifier with lower pressure water cylinder would be more suitable.
adding further advantages such as simple rcmoval of the piston for
repair works and the low headroom above floor. Proven main dimensiom:
for intensifiers are listed in table 12.
The air- or steam cylinder, the cylindcr bottom and cylinder fiange
and the piston of an intensifier with upper pressure water cylinder (sec
figs. 86 and 87) are made of cast iron (ASTM A-48 Class 35). For larger
sizes, the piston and cylinder flange may also be made of cast steel
(ASTM A·27 GR 60-30). The wall thicknesses are determined in accol'-
dance with the pouring practice in steam engine construction. If the
steam cylinder of an intensifier for a large forging press is too bulky for
transportation, it is customary practice to split it in two rings, 01' to instaH
two intensifiers. This solution (see fig. 52) has the advantage that th('
press operation can be continued with one intensifier in case the other
intensifier is being repaired.
During the upward mot ion the steam OI' aiI' are effective at the lo\\"er
piston area only. The downward motion of the piston is causcd by jt~
Tablo 12. Main Dimcl/s'iOIlS of E xi.stil/.(J IlttclI8'iJiel's of Steullt· and A ir-hyrZra1tlic l!'OI'(Jillf] Presscs
l~' o rJ! i Hg prc.'5-S 1'n t "Ils i tl er
--
Tll col'ctic" I Thco r,' - I lI n",
I' n':-\::-: . OPCI'llti Il g pl' cs."iurc :;1.""'" Ram l' SI<" "11 - .-;len ", l!lIsh- 1;sc[,blc li cal s llecu aL
S; l1glc H"m
wa te r wat e r 1 -1jl.l. /~cc .
a P;I(·jt ~' I J{itlll ci w. cylu!d c r si-ro lie )J r r.s::; urc COlllltl r load rod pll sh- rod I p rc;;'-;lI fC 'l '1
l tn' ~:; llr e
sl l'ukc CO Il :o;.U lfll'" dw . prCSSll rl' forcc wat t'r v ", o fpr",,-~
ti o l l drli\' r l'~' ( Q, :Q, ) (1) , : 1',) s pccd
(1 , p I
1)
, Q,
l Oll s i ll . p .... i. iu. " aiI. in. in. ps ;, 1). Î. t Ol18 in. tons u,,11. I L/sec.
I I
110 8 1/ 4 4,300 I 33/ 16 0.74 193/ . 24 1/ 2 115 - 17.3 31/16 1 153/ ,1 0.8 0.92 0.91 2. 55 ....
220 1 )3/ 4 4,300 3 1/2 1.7 27 1/ 2 29 1/2 115 - 34 43/ 8 I 3I1/ 2 1.9 0,90 0.93 2,75 Z
>-3
330 14 1/. 4,300 31/ 2 2.42 29 1/ 2 321 /2 130 - 44 5 40 1/ 2 2.7 0,91 0.93 3 t>l
44.0 14 1/ . 5,700 4 2.7 37 1 / 2 39 1/ 2 100 - 55 431. 50 3 0.90 0 .91 3.28 Z
UJ
550 15 3 / . 5,700 4 3.34 35 1/2 41'/2 140 11.5 65 5 1/8 58 1/ 2 3.7 0 .90 O.!H 3.6 :;j
lioO 17 1/2 5,700 5 5.03 35 1/ 2 47 170 - 84 6 78 :i.6 0.90 0,93 3,15 ....
t>l
S80 20 5,700 5 6,8 45 1/2 49 140 8.5 110 63 / 1 100 7.5 0.91 0.93 3.28 ~
UJ
1,100 221 /2 5,700 5 8.45 49 41 140 8.5 128 73/ 8 li8 9.3 0 .91 0 .93 3.4
1,350 24 1/ 2 5,700 (î 12 51 57 170 11.5 165 8 1/ . 152 13.2 0 .91 0 .93 3.18
1.650 27 1/ 2 5,700 6 15.4 55 57 170 - 205 9 1/.1 190 16.7 0,92 0.94 3,18
2,200 31 1 / 2 5,700 Ci 20 67 71 120 - 2·15 9 1/ 2 200 21.6 0,92 0,94 3,95
2,750 35J /2 5.700 8 33.6 79 89 120 - 295 1.1 270 36.8 0 9. 2 0 .92 3.7
3,300 38'/2 5,700 8 39.7 90 1/2 99 115 11 .5 330 1 Il 12 300 43 .5 0.92 0.91 3,95
4,400 44'/2 5,700 8 53 79 85 200 - 485 141/. 450 58 0.91 0 ,93 3,54
5,500 50 5,700 10 84 94 1/ 2 108 170 - 600 15a/4 550 92 0.92 0.93 3,6
0,600 3x 311./z 5,700 10 100 100 112 122 140 - 630 22 112 580 108 0.92 0 .92 4.00
8,800 3x 361/ 2 5,700 10 135 1101/2 126 170 8.5 830 29 3/ . 770 147 0.92 0.93 4.2
1 1,000 3x 40 11z 5,700 12 198 ]30 162 160 14 950 34 870 208 0.93 0 .92 4.5
16,500 3x 441/z 7,000 12 238 134 Hl2 21 :') 14 1.:100 50 1,300 258 0 .92 0.fl4 4. 5
>-'
O
102 PRESSURE FI,UID INSTALLATIONS
reciprocating weight and by the exhaust wator prossuro acting on the

piston rod. The oylinder head and the piston form a cushioning spaco
shortly before the piston has
reached its lowest position,
thus compressing the enclosed
mcdium and preventing the
piston from impacting into
the cylinder head. For the
reversed stroke the piston
may strike a pin arranged in
the cylinder flange 4 to 8 in.
before its highest position.
This actuates a shut-offlinkage
and thus reverscs tho control"
automatically, connecting the
exhaust line to the bottom
cylinder space, and estab-
lishes a pressurc balance on
both sides of the piston. For
this purpose, the top cylinder
space is connected to the
exhaust steam line. Actuation
of the shut-off linkage may
also be effected by a cam,
which is operated by a rollor,
mounted to the intensifier rod
(fig. 87).
In order to prevent heat
transmission in steam-oper-
ated intonsificrs from the
piston- to the intensifier rod
which are made of hard stoeL
a flanged connection is fre-
quently used with an intor-
Fig. 86. Air intcnsificr with upper pressure water
cylinder. Simt-oII device with stop rod, arraugel1 in mediary insul ating disc. Either
the eylinder flange. (By: Kreuser, Hamm.) this flange conneotion or fhe
wiper mounted to the inten-
sifier rod as per fig. 87 are the reasons for the long distance between thc
steam or air cylinders and the pressure water cylinder. These cylinders
are connected either by a housing of cast steel SAE 1045 or, when large
intensifiers are concerned, by four steel columns (AI SI 1035). On cold
air-operated intensifiers, the piston rod also serves as intensifier rod,
thus decreasing the distance between the cylinders and the hcadroom
INTENSIFIERS 103
considerably (fig. 86). Proven dimensions for piston- and intensifier rod
seals and the respective stuffing boxes are listed in table 6, p. 50.
The pressure water cylin-
der is made of forged steel
(AISI 1035); the explanations
given on p. 38 et seq. should be
considered for design. In order
to decelerate the piston move-
ment shortly before the upper
end position, the intensifier
rod is provided with a cushion-
ing pin, which decreases
gradually the flow area of the
outlet orifice in the pressure
water cylinder, before the
automatical shut-off device
becomes effective (figs. 86
and 87).
For limiting the intensifier
rod velocity, which should not
be exceeded, e.g., even il a
pipe bursts, a check valve is
installed direct1y at the inten-
sifier which opens during the
suction stroke of the intensifier
rod. During the discharge- or
working stroke the valve is
closed, leaving only an open-
ing required for normal oper-
ation, thus preventing an
overspeed of the intensifier
rod in case of sudden decom-
pression in the intensifier
cylinder, which might be
caused by erroneous control.
Besides the single-acting
intensifiers, sometimes so-
called stage intensifiers are
used. The design may, e. g. Fig. 87. Stearn intensifter with upper pressure water
as per fig. 47, incorporate a cylinder. Shut-off device with roUer and calll.
(.By: Kreuser, Hallull.)
shouldered intensifier rod,
which delivers three different amounts of pressure water; i. e. if only
the rod end are a is effective, or the annular ring are a of the shouldered
rod, 01' both are as together. This enables the press operator to perform
three single strokes of different size, the length of stroke being inversely
proportional to the press load attainable at the respective stage.
@ l~aQ5~
......
Fig. 88. Stage inten::;ificl' with tln'ee 10we1' prCS::iurc wakr cy!jnth~rs aud pbto!l rod diycrtillg 111l1':lgc.
(By: SchloemUlltl, Dii"eldorf.)
:Fig. 88 iIlustrates another design. The intensifier has three pressurc

water cylinders which can be controlled in such a ,vay tha,t either the
middle plunger OI' the two lateral plungers or alI thrce plungers together
cleliver the pressure water.
INTENSIFIERS 105
8tage intensifiers are suitable for forging presses which are used
temporarily as piercing presses with decreased pressure.
In steam intensifiers, the heat losses due to radiation, causing for-
mation of condenser water, are to be kept as low as possible by good
Airvessel
''I'F=~
i
1
Ii
Yig. S9. Steam il1tcll:,:,itirr witlt )0""1'1' J)I'f>~:-:;lIn~ wate r "rJillder and lllOving stuftlng box at tlw intt'll-
::::.i fi er
rod.
insulation of the cylinder, the cylinder flange, the control gears, and
the piping.
In most cases the inverted intensifier (figs. 89 and 90) having a lower
hydraulic water cylinder generate water pressure on the upward motion
of the steam cylinder, while the downward motion is effected by the
weight of the moving parts and by the pressure of the filling water.
There are two different designs of intensifiers with lower pressure
water cylinder. The first design is shown in fig. 89 and is distinguished
106 PRESSURE FLUID JNSTALLATJONS
by a piston in the pressure water cylinder which is sealed by a mov ing

stuffing box at the piston and a stationary stuffing box at thc cylinder.
The second design as per fig. 90, on the other hand, shows a simple
plunger piston which is mounted to a crossbeam and lifted by two
Ii' ig. 90. Stcam- anu nir intensHief with 10\\,('1' }-"' ig. 91. ])!'esR eylinder of a :3,300-ton forgillg
J)l'Cs:Sllre wa t er eylinder ano pist OIl rod div eding pres:; ",ith intcJlsifier i1rrilnged Oll t Ol'.
linkagr. (lir: Kreu"cr, Hamm.)
piston rods. The specifications for intensifiers with upper pressure water
cylinder also apply for the detail components of the two designs.
Upon erection the intensifier is located not over 30 feet from the
narrow side of the press, in order to ensure unobstructed press operation.
It has been tried on old presses to arrange the intensifier directly
above the press cylinder (fig. 91) in order to save space and to eliminate
the high-pressure components of the intensifier and the high-pressure
piping. Retraction of the intensifier rod is effected by a high cxhaust
INTENSIFIERS 107
water pressure. This design has been abandoned because of the many
drawbacks - such as high headroom, difficult repair work, and in-
creased defiection of the press due to the elevated center of gravity.
Such presses have largeIy been rebuilt.
2. Mechanical Intensifiers
The drive of mechanical intensifiers is exclusively effected by electric
motor and gear. The piston of the intensifier is reciprocated by crank-,
rack- or spindIe drive, thus performing an oscillating motion of the
press ram, which is under constant return Ioad.
Forging presses with crank gear intensifier may be suitabIy adapted
for cogging and planishing operations which require a predetermined
end position of the ram, permitting the Ieast amount of forging allow-
ance, which could otherwise only be achieved by using spacer bIocks
between the dies. Maximum numbers of stroke may be reached, as the
reciprocating motion requires no control gears. The penetration depth
must be chosen to allow for sufficient idle stroke for shifting and rotating
the workpiece.
The determination of the continuous motor output is based on the
average press requirements for cogging under maximum press Ioad.
The required continuous capacity is: -
Pen
H. P. = 33,000 -;; .
Key:
P = the maximum press capacity in lbs.,
e = the assumed penetration depth for cogging strokes in ft.;
the penetration depth may be put about 40 to 50% of the reciprocating
stroke,
n = the number of stroke8 which equals the rotation of the crank, in r. p. m.,
'/] = the coefficient of efficiency taking into account the friction-, flow-, leak-,
and volumetric 1088e.8.
For roughIy calculating the capacity, the coefficient of efficiency )/
is assumed to be Yj = 0.8, resulting in the equation
Pen
H.P. =26,400 or
H.P. = 0.0063 P·e·n,
if
P = maximum press capacity in short tons,
e = penetration depth in inches,
n = rotation of crank in r. p. ID.,
'/] = 0,8.
The rate of power input thus corresponds to the press requirements.

To overcome peak loads at each stroke, a fiy mass is suitably provided
at the fast-running motor shaft.
lOH Pl:tESSUI{E FLeID lNSTALLATIONS
For determining the fly-mass it may be assumeel that about 75%

of the eleformation work of a cogging stroke is to be performed by the
kinetic energy of the flywheel including the rotating masses, the drop
of rotation i during this stroke is to be kept within about 4 to 6 % of the
nominal rotation n 8 of the flywheel. The required moment of gyration
w·r2 is determined by the equation:
iri
'} LI E· 5,S6i)
w· r- .. ~ _ ( ~~o~ /1, 2
\vherein
,lE = transmitted kinetic energy in ft.-Ibs.,
w = weight of flywheel rim in lbs.,
r = radius of gyration in ft.,
i = loss of speed in %,
n s ~ speed before transmission of energy in r. p. m.
Frequently, an overloading of the motor is permitted, as the press
operates mostly with decreased capacity.
Furthermore, if the working conditions indicate that aHcr ti': seconds
of operating strokes an idle time of tI seconds follows, during which the
motor can recover again, the motor output to be determine el may be
decreased by the factor k = t tr; t . The work, which is not bcing done
E + [
by the motor during the time tr;, must be performed by the flywheel;
in this case a drop of rotation up to 15% may be pcrmissible, depending
on motor design.
The length of the reciprocating stroke is chosen 8 to 10% of the
press stroke for column presses ~nd about 12% for single-frame presses.
For calculation of the stress in the cylinder and gear parts, the same
formulas which apply for designing piston pumps are used, but permitt-
ing higher values for stresses and bearing pressures, as the nominal
pressure, on which the calculation is based, may be considercd as peak
pressure which only seldom occurs.
Fig. 92 illustrates a single-frame 550-ton forging press with inten-
sifier built into the back of the frame; the intensifier is activa te el by
crank with an optional constant number of strokes, 60 or 40 per minute.
The intensifier stroke is 153 / 4 in., the piston arca 37 1/ 4 sq.in. The pres;;
plunger of 185 sq.in. of piston area, thereforc, performs reciprocating
strokes of about 33/ 16 in. in conformity with the crank rotation. The
enclosed fluid oscillates between intensifier piston anel press ram. The
fluid pressure, which is kept to about 360 psi. by constantly loaelcel pull-
backs eluring the idle press stroke, increases eluring thc \vorking stroke
up to a value corresponding to the forging resistance anel is limited to
6,500 psi. by a safety valve arrangeel in the cylinder boUom. The pull-
backs are connected to a small accumulator of 720 psi. For adjusting thc
INTENSTFIERS 109
elevation of the reciprocating strokes within the possiblc plunger stroke

of 24 in., the volume of the oscillating fluid is either increased by adding
more fluid from the accumulator through a manual control gear or
dccreased by draining it into a reservoir (see "Controls") and is thus
adapted to the various hot stock sizes. The crankshaft is driven by a
pole-ehangeable motor of 180 H. P. through a flywheel and reduction
gear. Ry actuating a disc cluteh loeated on the gear shaft, single strokes
OI' part strokes of the press may be performcd. 1'he pressure oiI for
actuating the disc clutch and for lubric ating the gear and the intensifier
is supplied by a small gear pump mounted on the gear box.
Fig. 94 shows a crank gear intensifier for a 1,500-ton forging prcss.
The intensifier is of horizontal design and located separately from the
press. Two flywheel motors of 680 H.P. each can alternately be switched
on at 6000r 1,000 r. p.m. The drivingmotor works through a 20: loiI bath
double reduction gear driving a double-seated single-throw crankshaft
which therefore rota tes a t either 30 or 50 r. p. m. The connecting rod
drives the intensifying plunger through a spherically -guided crosshead.
Stopping and re-starting of the reciprocating motion of this unit
during the forging operations is effected by feeding the oscillating water
column into a low-pressure air vessel or back into the press cylinder
again. The application of a friction clutch in the gear would require
unbearable coupling dimensions for transmitting the torque.
Providing different crank speeds increases the operating range of
the press. Generally, a two-speed drive is equal even to a diverse forging
program.
If the numbers of strokes of a press can be varied, it might be desirable
to provide for reciprocating strokes of different lengths to be employed
at option. Even in this case two stages would be sufficient for the various
forging operations. The two stages can be arranged by a shouldercd
intensifier piston, thus obtaining two working areas, namely thc wholc
front al area of the piston or - by interconnecting with the annulus -
only the cross-sectional area of the piston rod. According to the abovc-
mentioned ratio, saying that the strokes are inversely proportional to the
effective piston areas, the stroke lengths are determined by sizing the
piston and piston rod. For both stages the maximum press load is of
same value due to limiting the pressure by safety valve. Another possi-
bility for staging is an intensifier design with the arrangemcnt of two
01' more pistons side by side, drivcn by an equally-throwed crank, and the
delivery of which may be fed into the circuit or by-passed at option.
Generally, a second and smaller size stroke is economical only in
connection with a speedy stroke sequence. It is advantagcous from the
technological point of view, as the forging deformation at each stroke
is kept to a small degree and a good grain structure of the forgcd picce
J NTENSIFIERS 111
Fig. 93. 1,6GO-ton four-columll forgillg press with crank grar intensifler. (By: Hydraulik, Duisburg.)
Fjg. 94. Crallk gear inten~ificr fur forglIlg prCSR a.s per fig. 93.
is attained. Considering an extended period of time, tlle deformat ion

work of the fast-running, short-stroke press may even be greater than
that of the slow-working press, despite its larger penetration depth.
The advantage of the rack- ar spindle-drive intensifiers over the

crank gear intensifiers is the longer stroke and the constant torque of the
drive motor. However, only a few installations have been built.
Fig. 95 illustrates the design of a horizontal rack intensifier. Thc dri\T
INTENSU' IERS 113
consists of a direct-current motor, which has only a small moment of

rotational inertia and may, therefore, be quickly accelerated, decelerated
or reversed. As per circuit diagram fig. 96, the motor is energized by the
-r -=------=--=-= =="\','" '"

II
II
II
II
II
II
II
/1
~\_ -- -
...... _- - - /
control generator of a flywheel converter and works with the Ward-Leo-

nard hoist, which is known from the reversing miU drive, so that even
the largest capacities of the motor can be completely controUed by small
8 Miiller, Hydralllic Forging Presscs
114 PRESSL:HE FLUID INSTALLATIONS
exciting currents. The control generator being coupled to fast-running

rotational masscs, allioad shocks arc absorbed by the kinctic energy of the
rotating masses by slip regulation of the convcrter drive, and an even
C'onsumption of current takes place.
The control gear actuates the drive motor with elcctric impulses
through the transmitter and receiver and allows for a sensitive stroke
adjustment.
Fig. 97 illustrates an intensifier, the drive piston of which can be
moved forward and backward by a spindle. Thc gear box houses a
bronze nut with multiple thread resting in a herringbone gear. This
.Fig. 97. lnteusifier with spindlc drivc for a. o,600-ton forging !)f'('SS. (Hy: S<H'l~, l)ii:-;~('ld()rf.)
gear engages with a pinion, the shaft of which is driven through a

ftexible coupling by a direct-current motor energized by an Ilgncr-
system. The spindle is connected to the intensifier piston by a cross tie
rod which moves with rollers on the base hame.
The illustrated intensifier operates in conjunction with a 6,600-ton
forging press. The intensifier rod has a diameter of 12 1 / 4 in. and i8
arranged for a stroke of 12 1/ 2 ft. The maximum operating pre8sure i"
7,700 psi. The spindle has an 8-eourse Acme thread with a 18.9 in. pitch
and 153/ 4 in. outside diameter. The motor is layed out for a con tinu om;
output of about 4,600 H.P. and 1,200 Volts, the rotation is 480 r.p.m.
The lowering and return speeds are 10 in.jsec., the rate of penetration
is 2 in.jsec. For cogging, the press performs 13 strokes per minute with
4 in. penetration depth and 2:~ strokes per minute for planishing.
c) Accumulator InstallatÎons
As a rule, electrically driven pumps deliver the pressure fluid \,hich
is stored in an accumulator. In order to protcct the accumulator instal-
ACCU:\lULATOR INSTALLATIONS 115
lation from contamination and dust of the forge shop, it is suitably

placed away from the press and is located in most cases in a separate
room. With accumulators, several presses may be operated independently
at the same time. The fluid pressure is usually kept between 3,000 and
4,500 psi. This pressure has proven to be the most economical one,
based on experiences
gained in the course of
time. Lower pressures
result in unfavorable
plunger-, piping-, and
valve cross-sectional
areas, whereas higher
pressures cause exces-
sive wear of the control
components and seals.
1. Accumulators
The oldest pressure
water accumulator,
which is not built any
longer, consists of a
long vertical cylinder,
inserted into a ba se
frame, with a simple
plunger piston on which
a weigh t of cast iron
plates or a ballast box
filled with scrap or ores
is suspended for generat-
ing the pressure water
(fig. 98). The disadvan-
tages of such a weight
accumulator are: con-
]<'ig. 98. Weight accunlulator for a volume of pressure water of
sidera bIe headroom, 240 gall. and an opcrating prcssure of 3,000 psi., tbc ballast
weight being abt. 330 tons. (By: Hydraulik, Duishurg.)
heavyfoundations, wear
of packings and plungers, impossible future accumulator additions, and
water hammer caused by the weight's inertia on sudden interruption of
the water flow.
In case of quick revers al of press motions the water shocks may lead
to an excessive incrcase of the operating water pressure, and may cause
piping- or cylindcr cracks, despite the arrangement of shock absorbers
which consist of small cylinders with spring- or air-loaded pistons for
cushioning. It would not be feasable to prevent or reduce the water
S*
shocks by decreasing the falling speed of the ballast wcights , which is ,

as a rule, v = 12 to 20 in .jsec. for a press speed of abt. 4 in .jsec., because
of the tremendous increase of the ac cumula tor dimensions.
These drawbacks led to the design of air-Ioaded hydraulic accumu-
lators. Their features are little space rcquirements (see fig. 99), the
a voidance of hea vy foundations,
Weight accumu/olor the omis sion of blow-off pres-
sure, possibility of later ad-
ditions , easy maintenanee, and
the omission of wearing pack-
ings.
The first air-Ioaded accumu-
lators for water resembled the
design of hydraulic pressure
intensifiers, air and water were
in separate cylinders; the air
pressure did not exceed 720 psi.
The aeeumulators were expen-
sive and ineorporated only a
few of the afore-mentioned
features.
During the further eourse of
development the air pressure
was chosen to be equal to the
wa ter pressure; air and wa ter
were in the same cylinder and
separated by a disk piston, the
movement of which actuated
the control gears for the pumps.
The disk piston was later
l"ig.99. Space rcquirements of an accumulator for a replaced by a float, until the
pressure water volume of 265 gall. and an operating
water pressure of 3,000 psi., if weight- and eOIll-
pressed-air loading are concerned. Total wcights: for
present designs , now proven by
eompressed-air loading abt. 33 tons, for weight- 30 years of service, completely
loading abt. 410 tons, ineluding the ballast weight
and steel structurc. eliminated any control gears
inside the water- and air vessels.
This piston- and floatless accumulator - with the common, but
frequently misleading designation compressed-air accumulator
usually consists of a water bottle and a battery of air bottles (fig. 100).
Normally, the water volume and the total volume are in al: 10 ratio.
The pressure drop between the highest and lowest water levels, i. e.
when withdrawing the useable pressure water, is abt. 10 to 12%. The
·c hange of state of air proceeds approximately isothermic up to 720 psi.,
but at higher pressures, due to the influence of the vessel walls, it,
ACCUMULATOR INSTALLATIONS 117
proceeds polytropically according to the equation :

Pl V t = P2 V 2n ,
the polytropic exponent n being 1.29 to 1.3 for an operating water
pressure of 3,000 psi.
The dimensions and
numbers of air bottles for a
certain total volume are
adapted to each other in
view of the costs of the
different bottle sizes. For
small accumulators, the wa-
ter- and air volumes are
frequently accommodated in
one bottle, while large accu-
mula tors consist of many air
bottles and several water
bottles (fig. 101), which are }'ig. 100. COlllpresscd·air aeculllulator with two COlll-
Illullicntillgly coullectcd water bottles for a compre,sed
connected by communicating water water volullle of 265 gall. each aud 3,000 psi. operatillg
pressure. (By: Hydraulik, Duisburg.)
lines. The inside diameter of
the water bottles is chosen such that the highest lowering speed of the
water level does not exceed v = 8 to 10 in. jsec., otherwise the water sur-
face would be disturbed, which could cause occlusions of air in the piping.
Fig. 101. Compresscd·air accumulator for a pl'cssure water volume of 800 gall. and 3,000 psi. operating
water pressul'e. (By: Hydraulik, Duisburg.)
llH PRESSURE FLUID lNSTALL\TIONS
The ,'..atcr and air bottles are scamlcss and madc of ductile matcrial.
either drawn or forged. They may also be welded for pressures up to
abt. 1,500 psi. The calculation of the wall thickness may be carried out in
accordance with the AD-specifications 1 ). According to ~L\D-Shcet TI 10.
the waJl thickness t in mm is
t= diP + c.
')') MF
_.a-,sF- 3 Ţi
Key:
di
inside diameter in in.,
~
pinternal pressure in psi.,
~
MF ~ coefficient of strength in lbs.jsq. in.,
SF ~ safety factor,
c ~ supplement for wall thickness in in.
With seamless drawn vessels, the degree of forging which is Iower in
radial direction than in longitudinal direction and which arc not com-
pletely free from forging grooves, a safety factor of SF = 1.8 is suitably
applied. The supplement c equals the permissible amount of reductioll
in waU thickness of 10%. As per specifications of AD-Sheet W 122) thp
material AISI 1040, having the average tensile strcngth of MF' =
43,0001bs.jsq.in., may be used, but makers of accumulator bottle:-;
also use materials of their experience.
The water pressure for testing is 50% above the maximum operating
water pressure. AU calculations and tests are to bc performed in accor-
dance with the specifications of the Tcchnischer Dberwachungs-V crein
and the Pressure Gas Law 3 ).
Bottoms of forged and welded bottles should preferably bc of semi-
circular OI' ellipse shape. When forging the bottom of a cylindrical hollm,-
body, the bottom thickness increases towards the center duc to the up-
setting operation.
Drawn bottles arc provided with a fiat bottom with a thickness of
h = 1.5 to 2 t, t being the wall thickness of thc jacket. The opposite
bottle end is drawn to a neck-like shape.
Dimensions of standardized air- and water bottlcs arc given in
table 13.
The boss for the bottle orifice is in bottom center and extends a little
bit into the bottle to allow for the dirt and foreign matters to deposit
on the bottom. In order to attain a smooth water surface. the boss eIld
is blocked and provided with lateral orifices.
') Arbeitsgemeinschaft Druckbehălter (AD) Merkblătter B 10 and \V 12.

~) German Standards.
3) Sammlung der Unfallverhiitungsvorschriften 17, 18, 19, Druckbehăltcr, des
Hauptverbandes der gewerblichen Berufsgenossenschaften, Kiiln: Heymallll.
ACCU)iUI,ATOR INSTALLATIONS 119
Table 13. Dimen8ion8 for Accumulator Bottle8 (Extract from DIX 2762)1)
With Converted Figures
~E '" Opcrilti~~ .prcssurc 1 1,500 1 2,300 I 3,000 I

, 1:
3,600 I 4,5oo~ ..'" o
"'"
~~ =
;; bD tU
o ti(
=
o:;;~
~n l1. Dimensions in in. Rnd wciJlht- in 1bs. in .
1
Quts.ide diameter 15 1/2 16 1/ .
153 / . 16 1/ 2 17 3/818
Inside diameter 14'/8 141/8 14'/8 141/8 141 / 141(8
66 \;llall thi ckness 11/16 13/ 18 1 13/18 P/a 115/ l6 2'12
Length 106 108 108 110 110 U2
Fini hed weight 1,000 1,380 1,760 2,100 2,780 3,580
Qutside diameter 17 1/ . 171 / 2 18 181 / 2 191f4 20
Ins ide diameter 153/ . 153/ 4 153/ .153/ . 153/ . 153/.
106 WalI thicknes 3/. 7/ 8 1'1. P /a P/. 2 1/ . 2' /2
Length 136 138 138 140 140 142
Finished weight 1,700 2,140 2,640 3,330 4,500 5,500
Qutside diameter 231 / . 231 / 2 241/ 4 243 / .253/. 27
Inside diameter 2PJ. 2P/. 21 1 / . 211/« 211/, 21 1/ .
167 WalI thickness 1 1118 P/? 13/, 21 1. 21/8 3 1/ 8
Length 124 126 126 128 128 130
Finished weight 3,030 3,520 4,350 5,200 7,000 9,500
Qutside diameter 231/ . 23 112 2411. 243/ . 25 3/ . 27
lnside diameter 2 Pl. 2P/4 21 1/ . 2P/. 21'/4 21'/.
265 ""aH hickness 1 1'/,. 1' / 2 1 31. 21/ , 21/s 3 1/8
Length 185 187 187 189 189 191
Finished weight 4,350 5,160 6,400 7,700 10,200 13,800
Qu tside diameter 25 251/ 2 26 27 28 29 1/ 2
Inside diameter 23 23 23 23 23 23
330 Wall thickness 1 Pl~ F /2 2 2 1/ 2 3 1/ . 3' /
Length 197 199 199 201 201 203
Finished weight 5,400 6,500 7,900 9,900 12,800 16,600
Qutside diameter 27 27 1/ 2 28 29 30 1/ 2 31 1/ 2
Inside diameter 25 25 25 25 25 25
425 WalI thickne 1 Pl. 1'/2 2 23/ . 3 1/ . 3 1/
Length 218 220 220 222 222 224
Finished w eight 7,300 8,400 10,000 12,300 16,700 21,000
Qutside diameter 29 ' / 2
293 /., 30 1 / 2 3P/2 323 / , 34 1/ ,
I nside diameter 26 3/ .263/ , 263/ , 263h 263/ " 263/ 4
530 Wall t hickne P /s 1'/2 F /$ 23/ 2 3 33/4 3'/
Length 234 236 236 238 238 340
F inished weight 8,600 10,100 12,700 16,500 20,500 26,400
Qutside djameter 331/ 2 34 35 36 37 -
lnside diameter 30 1/ 2 30'/2 30 1/ 2 301/ 2 301/ 2 -
660 WaU thickness 1'/2 P/, 2 1/ , 23/. 3 1/. - 4
Length 228 23 O 230 2321 232. -
Finishen weight 13,200 12,90O 16,400 20,600 26,000 -
The nominal pressure of 3,000 psi. is to be pl'eferred to any other pressul'e stagC'.
Material: AISI 1040 and special materials.
Calculation: Wall thickness as per specifications of the Arbeitsgemeinschaft Druck-
behălter (AD).
Tolerances: Outside diameter including unroundness: ± 1% of the outside dia-
meter. Wall thickness: + 15% -10%. Length: ± 2 in.
1) See also DIN 2760 to 2763.
The bottom of the air bottles is provided with a plug to drain the
condensed water.
For corrosion protection the inside of the bottles is asphalt-coated.
Principally, the usable water volume of the ac cumulat 01' must be
sufficient to meet the pressure water requirements for the largest stroke,
including the demand exceeding the amount of pressure water delivered
by the pumps. An exact determination of the required working volume,
therefore, has to be made in accordance with the installed pump capa-
city. The pump delivery is generalIy neglected, however, in order to be
able to complete a commenced working stroke if the pump fails. The
largest requirements on a forging press occur in case of fast successive
strokes 01' large working- and re turn strokes, e.g. for upsetting and
piercing. If there are no further requirements to be met which would
necessitate an exact determination of the consumption, the working
volume of the accumulator would be sufficient, in view of proven instal-
lations, if, independent from press size, there is enough volume for a
working stroke of 50 to 55 in. 01' for several strokes totalling the same
amount, and for the return strokes. For rough calculations, we thus
obtain a usa bIe formula for the working volume: V = 13 to 14 (A + Al)
in cubic inches, if A in square inches is the press ram area, Al in square
inches the return ram area, Al averaging to about 8% of A.
Basically, the vessels for accumulating the pressure oiI may be
designed like the pressure vessels for water, however with nitrogen
loading to prevent any explosive oiI-aiI' mixture.
2. Pumps
The pumps for delivering pressure fluid iuto the accumulator must
meet the largest average consumption. If the highest water level in the
accumulator is reached, the delivery is shutoff automatically and starts
again 10 to 12% of the working volume has been withdrawn. By this
re-starting of the pump delivery, which is delayed by the amount of the
so-called oscillating stroke, the frequent starting and stopping of the
pump is avoided, if the average consumption is lower than the installed
pump capacity, which is true for most forging operations. If the pump-
ing unit consists of two or several pumps, a larger oscillating stroke may
be provided for the second and folIowing pumps, so that alI pumps
operate only in case of continuous consumption of the largest amount
of fluid. The distribution of the total capacity over several pumps is
desirable, as in case of repair works at one pump forging operation can
be continued with the other pumps.
The determination of pump capacity for accumulator operation is
based on the largest continuous average press consumption. This oecurs
usually when pre-forging (cogging) under maximum press load. The

amount of pressure fluid used for one cogging- or piercing stroke might
be considerably larger than for a number of consecutive cogging strokes,
but there is, however, enough time for the pumps to refill the accumulator
~ig. lOZ. PrcsRure water unit with a 790 gall. cOffipressed-air aecllffinlator and two horizontal PllffiPS
for a total eapacity of approx. 1,000 H.P. (By: Hydralllik, Duisburg.)
before the following long stroke. Therefore, the pressure fluid consump-
tion for cogging or piercing is not a decisive factor for determining the
pump capacity, but for the working volume of the accumulator (see
p. 120).
The amount of fluid Q to be delivered by the pumps for continuous
operation in order to meet the average demand for the main- and return
strokes, is determined by the equation
n
Q = (A e + a hR) -- in cu. ft./sec.
fJh
Key:
A = the main ram area in sq.ft.,
e = the depth of penetration for cogging of the upper tools in ft.,
a = the return ram area in sq.ft.,
h n = the retum stroke in ft.,
n = the required number of strokes per minute for cogging,
1]h = the hydraulic coefficient of efficiency which considera the volumetric and
leak losses of pump, press, and piping.
122 P RESSC R E FLU ID I NST ALL ATIOX S
The r equired eapaeity at the C'rankshaft of the pump j" :
where
p ~ t he fluid pressure in the main cylinder in psi. an d
'Y/m ~ the mechanical coefficien t of efficiency, conRidering the frictioll losRCs in
t he pump and the flow losses up to the press.
If, fo r rough ealeulations ,
Q = 0.08 A in sq.ft. ,
hR = 1.5 e in it.,
1;'11 = 0 .9,
1>" = 0.8,
t hen
in eu . ft .!sC'C'.
a nd
Pe 1/
H.P. =2 1, 200
if the press load is introdueed in tans .
T able 14. D imellsio1l8 f OI" Forging PreS/ies u,nd P ou'er Fluid S la fl:o/l s
Presg d i mensions PTess cfftc: cIlC\' Power Ou;'\ s t nti ol1

wh II cogging
.e,
'" - .. i::-
"',-..-:::
-;'"' z
.§ '""2 "
'- <> C
]~ =-
E~
~
<:
-~-::.-:: -
.: "
g:;
el
:§e ~~
"'o E '"
...
o;
""
L~
..:~ -:". E
~ ,~~::
~.;:. .::::0:::: ~ 1c
~o
E~
§~ t::
c::.. '"§ ~11
§& ::: ;.(
~~
~;;: '" :Il ~
,..~"... e. '"
" ~ ~~
o~
~g :::;=: ~!:
~ tr.. o~ Z1: <> 0.
0...-= ~ p:; :tt
P
tOIlS
D
in.
It
in.
D Tl
ill.
D .•
in.
P
psi.
"
1/111il1. in.
e
""
in .
Q
gpm. 1 1!.P.
11
ab t. abi.
1"
gall .
1
550 22 1/ 2 27 1/ 21 2 x 43/ . 55 19/ ,6 23/ 8 183 380 106
700 25 311/2 2x 5 3 /a 50 P/~ 29/ 16 226 475 132
880 28 1/ 2 351U2x 6 45 P3/1G 23 / 4 278 580 164
1,100
1,400
1750
31' / 2
35 1/ 2
40
39 1/ 212x 6 1/ 2
47
55 2x
7 11.
2X 81 / .
lLooo 40
35
30
21 / 4
29/ 16
I 215/ 16 330 700
33/ S
4
424 890
5301,100
200
238
318
2,200 3x 26 63 1 2x 9 26 2'/8 4 3/ 8 6351,330 384
2,750
3,500
3x 29
3x 32
71 2x 1Q1/.
79 2 x l P /2
22
18 [3
3 '1
. 13 / 16
5
53/.1
768 1,600
925 1,950
477
595
4,400 3x 37 87 2 X121/212X71/2 15 47/16 63/4 1,1402,400 768
5,500 3 x 4F/~ 95 2x 141/. 2 x 83/ 41 12 51 /~ 77/ 8 1,3502,800 965
II
I
7,000 3 x37 100 2 X12l/212 X8 10 9 990 13,300 795
8,800 3x 42 110 2 x 141/ 4 2 X 8314 53/4
6 9 / 16 10 1,150 3,800 1,000
I
1
11 ,000 3x 46 1/ 2 118 2 x 153/~ 2x lO 1. 4,500 7 7 1/ 16 11 1,:350 1~,650 1 ,~70
14,000 3 x 52 1 126 2 x 171/22 x 12 6,5 71 / 2 12 1,670 0,500 1,a90
17 500 3 x 59 134 2 x 19 2 x 14 6 77/ 12J / . 2,070 6,800 2,000
ACCU:vrULATOR INSTALLATJONS
Table 14 gives maximum values for the number of strokes n and the
penetration depth e, when cogging, as well as the horsepower require-
ments for the pumps and the economical working volume of the accumu-
lator; they may also be used as basis for determining the capacity of
boiler- and compressor units for steam- and air-hydraulic forging presses_
By means of table 11, p. 91, the pump capacity for accumulator
operation may be compared with the direct drive of forging presses. For
this purpose, the values of table 14 for the respective press sizes have
been converted to a pressure of 5,700 psi. and are listed in table 15;
they indicate that, even for the low operating speed averaging 2 in.jsec.,
considerably larger pumps have to be installed for the direct pump drive
than for accumulator operation. The relatively low continuous output
of drivc motors for the direct pump drive results from the especially
high overload capacity of the motors, the arrangement of large fiywheeh;
to overcome the peak loads and the permitted large drop of rotating
speed of 15%.
The specifications on p. 82 et seq. also apply for feed pump design. Bes-
ides the triplex pumps for pressure water and the multiple-piston pumps
for pressure oiI, described there, centrifugal pumps may also be employed
Table 15. Gomparison between Accumulator Drive and Direct Pump Drive
AccUrDulator tlri,"" Pir 'cţ 1'1111111 tlri\'c
a S per lf,blc U I wltll 1) ~ 6,OOU 1'.1- os P r s peciflcn tl o ll s in table 11

I
J'r $.';;';
l'rCllsurc I Pu III 1)
(lrivc
I Con-
1 ., I
1 r("~:"lIrC slim ption
'O)l7
])nml") clri\' ('
.Y
OII'
SUlllptio ll
at v =
CfI"aCity SlImptio ll
(111. = 0.9) 2 in ./scc· ,
I
p 1) Y ('1h = 0.9) f!
COli ti-
PNlk Q
Q Q ItU O U ~
t OIl,; 11:Si. I H. I' , gpm . p,.-i. gJJm , H.P. H .1>. gl'Hl,
1:70 3,000 1,000 477 6,000 238 600 1,200 284

2,500 3,000 1,460 700 6,000 ~~4 6 90 2,000 450
4,400 3,000 2,400 1,140 6,000 570 1,800 4000 800
7,700 4,500 3,550 1 070 6,000 50 2, -00 6,500 1,400
for feeding the accumulator - which operates with a fiuctuation of

pressure up to abt. 10% - because they are particularly economical
due to little space requirements and low initial cost.
3. Auxiliary ElJuipment
Parts of the auxiliary equipment of an accumulator unit are the

automatically operating control gears, the armatures, and the high-
pressure compressor.
124 PRESSURE FI,UID INSTALLATIONS
The automatical operations are:

1. Interruption of the pump delivery if the accumulator is filled,
2. Return to pump delivery after a certain amount of fluid has been
used up,
3. Shutoff of the connecting piping to the press to prevent the inlet
of air or gas respectively,
4. Indication of the fluid level.
There are a number of basically different designs for the aforc-
mentioned operations; in most cases, the control gears are actuated
by the fluid level. Mechanical parts, such as piston or float, for trans-
mitting the oscillating movement of the fluid level to the control gears,
are no longer used because of unsatisfactory operation on previous
designs.
If the control gears are not actuated by the fluid level but by thc
fluctuations of pressure, care must be taken that any possible pressure
losses due to leaky air lines or absorption are carefully checked and
replaced, otherwise 110 correct determination of the actual fluid level is
possible, which would cause unpleasant operating troublcs.
The mode of operation of a very common control for a compressed-
water accumulator is illustrated in fig. 103.
The electrical control gear has two chambers connccted with each
other by a communicating bore, the lower part of the chambers is filled
with mercury and the upper parts arc connected to the air- and water
bottles of the accumulator.
Several contacting electrodes are arranged in the air space of the
control housing. If the water level in the accumulator raises, also the
mercury level in the air space of the control housing wiU raise, the mo-
tions being inversely proportional to the specific gravity of thc two
fluids. Upon contact of the contacting electrodes with the mercury, low-
voltage current circuits are closed and solenoids are indirectly actuated
through relays in the control panel which get thc exciting currents from
the main supply line, thus actuating the hydraulic pilot control for the
main valves. The valves cannot be opened or closed directly by the
solenoids because the required forces are too great.
In the position shown with the lowest water level, the longest elec-
trode contacts the mercury. If the water consumption continues, an air
space formed by lowering of thc mercury level opens the last current
circuit and by dropping of solenoid 1 the pilot control gear for the auto-
matic shutoff valve is reversed. The bore bl underneath the lifting rod
for the automatic shutoff val ve al is connected to the return line by the
opened valve 2 of the pilot control. The shutoff valve al is closed thus
preventing a water intake from the accumulator and air escaping into
the piping.
If the water level in the accumulator rises due to the delivery of the
pumps, the water fiows through check valve CI aud shutoff valve al'
which acts in the same direction, aud the pilot control gear is uot reversed
~
::;::
~------------------------------------{~
/
IIl;JnX:I ~=H--J- . _ ._ o _ o __ o- 0 - o_o ~
."
"<;
~ '" ~
'>.."" o~ t5
-l:::
~
~
~
~
i';'- c ....
~ .s.
~
,i.: ~
'" ~
again before the uext-to-the-Iast current circuit is closed by lifting of the

solenoid 1, due to the rising mercury level. The valves 1 and 2 are being
opened or closed respectively. The bore bl is charged with compressed
water; the lifting rod opens the shutoff valve al' again connectiug the
]26 PHESSURE FLTjID TNSTALLATIOKS
accumulator with thc prcsses. As the electric al circuit is designcd in sueh

a way that reversing or closing of the shutoff valve al does not take
place before the opening of the eurrent circuit has been cffected by tl10
longest contacting electrode, the time delay between thc reversing
operations is achieved by an oscillating stroke in the accumulator, thus
preventing a disturbance of water- and mcrcury levels and, eonsequently,
an undue switching frequency.
If the mercury level rises up to the la8t contacting pin, in accordance
with the highest water level in the accumulator, the cxciting circuit
for solenoid II of the pilot control for pump by-pass valvc el is opened by
thc closed low-voltage current circuit. Solenoid II lowers, valves 3 and 4
are being closed or opened respectively, bore dl behind the lifting rod for
by-pass valve el is connected to the return water line. The pumps deliver
then the water through by-pass valve el and the return water line into
the reservoir again. Check valve CI prevents a discharge of water from
the accumulator during the idle run of the pumps.
Pump delivery into the accumulator is effected again by closing
hy-pass val ve el after the next-to-the-Iast contacting electrodc has been
released, i.e. after one oscillating stroke has been performed, as de-
scribed in mode of operation of the shutoff valve.
Switching-off the pump motors at the highest water levcl 1Il thc
accumulator instead of by-passing is not suitable on account of the
high switching frequency that might temporarily occur in a forge shop.
Moreover, the use of clutches for idle run is refrained from, as the hydrau-
lic by-pass arrangements are simpler and cheaper.
The water le veI is indicated on the main control panel as well as on
the operator's pulpit by a signal lamp which is connected in the lo\\"-
voltage circuits for the solenoids.
Malfunctions of the controls might he caused hy failure of electric
eurrent. In order to prevent any hazard to the press operation in such a
case, the controls must be arranged such that the shutoff valve al j"
closed and the pump by-pass valve el open on power failure.
Further well-known control designs for accumulators are schemati-
cally illustrated in figs. 104 and 105.
The compressed-air loaded accumulator as per fig. 104 consists of CI
water bottle 1 and of several air bottles 2. Connected to thc watcr boUle
is a communicating pipe 3 which may be shut-off from the water botUe
by the valves 4. Into the control housings 5, 6, and 7 valve rockers are
incorporated which are provided with a float 8 at one end and a per-
manent magnet 9 at the other end. The rising and lowering water levels
in the ac cumulat OI' cause a rotation of the rockers by the floats and thc
magnets are moved. Arranged at the control housings. out;;ide the preti-
surc ehamber. are eleet,ronic switches with mcrcury eontaets 70. ]].
ACCUMULATOR IKSTALLATIONS 127
and 12 (mercury switches), which are inserted into the sides of each
magnet, thus closing or opening electrical circuits.
If the water level has reached its highest position, the float 8 in hous-
ing 5 is lifted and the contact in the mercury switch 10 is broken by the
magnet. Thus the relay on control panel 13 is de-energized. The solenoid
Z 2
compresSOl'
111
Fig. 10-1. Control circuit of a COlllpl'(·:..w.ed-air acculllulator witlt electrical togg1e ~"yit('hcl'3.
(By: Srl1loclIlann. lJii,seldorf.)
14 becomes de-energized and by-pass valve 16 is opened by pilot control

lS. The pump runs idle by delivering the water back into the water
reservoir, while check valve 17 prevents a dischargc of the ,vatcr from
the accumulator.
If the water level drops again by using pressure water from thc watcr
bottle, and if the float 8 is lowered in housing 6, the respective magnet
makes contact in the mercury switch 11. The current circuit thus pro-
eIuced in the mercury switches 10 and 11 lifts the solenoid 14 at the
s\yitch board by means of a relay. The controlled by-pass valve 16 is
shut again by the pilot control gear 15, and the water delivered by the
pumps is fed into the water bottle through check valve 17.
If the withdrawal from the water bottle is largcr than the pump
delivery, the water level in the water bottle may reach its lowest position,
thus lowering the float 8 in the housing 7 and breaking the circuit in thc
electronic switches by the appertaining solenoid. The corresponding
relay in the switch board is released. The solenoid 18 becomes de-ener-
gized, the automatic shutoff val ve 20 is shut by pilot control gear 19,
thus preventing further intake of pressure water. At the same timc,
accustical or optical signals 21 and 22 indicate that the accumulator is
empty.
If the specified pressure in the accumulator is exceeded, a contact
pressure gauge 23 closes a circuit and stops the pump motor by a relay
on the switch board; moreover, the automatic safety valve 24 gives
response.
Valve 25 permits manual shutoff of the accumulator.
In figs. 105a and b, B illustrates the water bottle and BI the air
bottle. Mounted to the water bottle is the control bottle C, in which a
small float E oscillates freely with the water level. As long as the water
level oscillates between the two connecting pipes which can be shut off
by valves A 2 and A3' the water column in control bottle C that carries the
float E oscillates evenly in accordance with the water column in bottle B.
If the water level in bottle B rises beyond the upper connecting pipe,
the water column in bottle C that carries the float E performs a shorter
stroke than the column in water bottle B. The air space in bottles C
and P is sized for a certain float stroke for the common pressure fluctu-
ation of abt. 10% between highest and lowest water levels in bottle B.
The stroke is kept equal for aU accumulators in order to maintain one
model for all regulating devices.
The rod of floa t E bears an iron core F which moves in a non -magnetic
tube D. The tube is surrounded by primary coils 1 to IV, energized by
continuous current, which are kept within a certain distance from each
other by spacers, and which generate induction currents in secondary
coils, when the iron core passes through, for controlling solenoids Mal
and Ma 2 • WI houses the relays and a transformer for a voltage of 24 V
for the coils 1 to IV and W 2 houses the relay switches and the fuses.
O is a signal board with four differently colored signal lamps 5 to 8.
A manual shutoff valve Al is arranged between the automatic shutoff
valve G and the water bottle B.
Fig. 105a illustrates the control device of the accumulator with
lowest water level in bottle B and with closed shutoff valve G. The
lamps 5, 6, and 7 light; the pumps work; the piston a of the pump
by-pass device Z is firmly pressed against the scat by pressurc water
ACCUMGLATOR INSTALLATIONS 129
-
:3
9 Miiller, Hydraulic ]'orging Prel'e,

from the pilot control gear y. The pump water fiows through check
valve b and shutoff valve G, also acting as check valve, into the water
bottle B. The water level rises and also, simultaneously, thc fioat E with
the iron core F in the control bottlc C.
If the iron core F moves through the coil 1, no switching operation
is performed, as the control voltage switch U has broken the circuit..
If it enters coiI II, solenoid Mal is energized, lifting t.he shutoff valve
G by means of spindle L, lever K, and spindle 1 and keeping it in the
opened position, thus permitting again further water intake from t.he
accumulatoL The lamp 6 extinguishes.
If the water level rises further, the iron core F passes through coil III
without causing a control operation, as the circuit of this coil is opened.
On entering into coil IV, fig. 105b, the circuit of solenoid Ma 2 is broken,
thus connecting the upper side of control piston a to thc return water
line. The water delivered by the pumps lifts piston a and returns int.o
tank. Check valve b prevents a discharge of pressure water from thc
accumulator; lamp 7 is extinguished, lamp 8lights.
If the water level drops again, and if the iron core passes through
coiI III, solenoid Ma 2 is energized. The pilot control gear y connects
the control piston a to the pressure water line. The pumps deliver again
against pressure through check valve b and the automatic shutoff valve
G into the accumulator. The shutoff valve G does not close before thc
lowest water level is reached and the iron core is positioned in coil 1.
On moving downwards of the iron core through caiI 11 no control ope-
ration takes place.
The electrical actuation of the control gears permits thc installation
of the ac cumula tor in any distance from the pumps. It is common prac-
tice, therefore, to place the accumulators close to places of consumption
in plants of an extensive line system, while the pumps are arranged in a
common room. The use of several accumulators instead of a central unit
has the advantage of avoiding water hammer due to long lines and drop
of pressure in case of simultaneous operation of several presses, eaused
by tapping of pressure water which fiows in a common direction.
Accessories of a compressed-air loaded accumulator are a manual
shutoff valve arranged directly at the pressure water connection, manual
shutoff valves for the air bottles, a safety device against exceeding a
certain maximum pressure by switching-off the pump motor and a
switch board with relays and the appertaining push-button switches
for the solenoids, and a circuit breaker for the main supply, a trans-
former, the fuses, and the indieating lamps for chccking the water levcl
and the voltage.
For charging the accumulator with compressed air, onc or several
small multi-stage high-pressure compressors with direct, motor drive
HYDRAULIC LINE SYSTEMS 131
of 5 to 25 H. P. are used. For initial charge, the compressor has to run

uninterruptedly for several days, while it is used later on only occasionally
to make up for any losses due to absorption or untightness.
d) Hydraulic Line Systems

lncluded in the line system, which carries the pressure medium from
the pumps through control gears to the press and its auxiliary equipment
and the de-compressed fluid back to the suction orifice of the pump, are:
air vessel, storage- and cooling tank including the required armatures
and safety provisions, as well as the piping and shutoff devices.
1. Air Vessels
In conjunction with an accumulator unit, the air vessel serves as
low-pressure accumulator for fast advance of the main ram, and also
for receiving the de-compressed fluid from the main cylinder and the
auxiliary cyIinders, unless they are emptied - for certain reasons -
into a pressureless reservoir. Therefore, the main cylinder is charged with
high-pressure fluid from the accumulator only during the actual working
stroke.
During each working cycle, more fluid flows into the air vessel than
is taken out by the press. The excess fluid is returned to the tank by an
automatic overflow device and from there it is fed to the low-speed
accumulator feed pumps. An overflow is not required for pressure pumps
for direct press drive or for high-speed pressure oiI pumps, as they are
directly fed from the prefill vessel.
In most cases, the compressed-air of the plant of abt. 115 to 150 psi.
is used for generating the low pressure in the prefill vessel. Based on a
normal fluid level in the prefill vessel, the largest fluid intake, generally
used in calculations, is equal to the difference between the stroke vol-
ume V p of the press rams and the return volume V R of the pullbacks.
At this lowest fluid level sufficient pressure must stiU be available in
order to overcome the flow resistances in filling pipe line and prefill
valve for the caiculated approach speed of the press ram as well as the
difference in height between prefill vessel and press cylinder. In order
to ensure enough safety against cavitation in the filling pipe line, the
pressure in the prefill vessel at lowest fluid level is chosen 15 to 30 psi.
higher than calculated. For oil operation, the decisive factor for the
minimum pressure at lowest oilievei is generally the required feed pres-
sure for the fast-running oiI pumps, being approximately 45 to 75 psi.
depending on pump construction.
The highest fluid level is indicated by the amount of filling which is
reached if the volume V p is added to the normal fluid le veI and if it is
9*
PItESSURE FLUID INSTALLATTONS
assumed that a simultaneous withdrawal by the pumps or by over-

flowing into the reservoir does not take place. In this case the pressure
may only raise up to the fluid pressure generated by the press pullbaeks.
taking into aeeount the weights to be lifted and the friction in guide
bushings and stuffing boxes of the press cylinder (sec "Return Deviccs").
For determining the required gas volume in the prefill vessel, isothermic
change of state of the gas may be assumed with sufficient exactness as
per the equation
wherein the pressures have to be substituted with their absolute values.

In order to avoid a disturbed fluid level, the intake pipe is hori-
zontally arranged 8 to 12 in. below the lowest fluid level, leaving enough
spaee below the intake pipe for deposit of dirt and foreign maUers. The
total volume of the air vessel ineluding the aiI' eushion and the space
for deposits is usually Va = 4 to 8 V p.
For oiI operation, a total volume of the aiI' vessel Vu = 1.5 to 2 O.
where Q is the installed pump delivery, in order to provide for a suffieient
amount of circulating fluid, for keeping the heat and aging of the oiI as
low as possible.
In case of large distance between aiI' vessel and press, there is a
possibility of water hammer in the filling pipe due to the inertia of the
fluid. In order to avoid this drawback, a small intermediate aiI' vessel is
arranged in the filling pipe directly at the press for cushioning thc
fluctuations of pressure due to accelerated 01' decelerated fluid movement.
Instead of an aiI' vessel, sometimes only an elevated tank without
compressed-air loading is used for small water-operated forging presses.
It requires less maintenance, the disadvantage, however, is the larga
flow area of the filling pipe and the prefill valve at the press due to
low water pressure; moreover, aceelerated 01' decelerated press ram
movements may cause, similar to remotely located prcfill veRsels, water
hammer in the filling pipe, which can also be avoided by an aiI' vessel
directly arranged at the press cylinder. In this case the piping betwccll
aiI' vessel and elevated tank may be of smaller cross-sectional area.
Nowadays, prefill vessels are exclusively made from sheet steel anei
welded. For calculation of the wall thicknes:;, the AD-:;pecification:;l)
provide detailed basic information. Within the range of common dimen-
sions and operating pre:;sures the following formula i:; usea for dekr-
mining the wan thickness:
dop
t= Yl'
+0.04.
2 81' v
1) Arbeitsgemeinschaft Druckbehiiltcr, Mcrkblăttcr B 1 his H :l.

Key:
t ~ wall thickness in inches,
do ~ outside diameter in inches,
p ~ maximum operating pressure in psi.,
yP ~ yield point of the wall material in psi.,
SP ~ safety factor, which is 1.5 for materials with guaranteed quality,
and 1.8 for materials without guaranteed quality,
/. ~ joint efficiency factor of the weld seam as compared to the fuU
sheet, which is v ~ 100% for a seamless construction and 1) ~ 80% for
a welded longitudinal seam, unless a welding procedure is applied
which guarantees a joint efficiency factor of 100%.
For flanged and dishcd bottoms the wall thickness is determinecl
41
by the formula
t= Pp f3 + 0.04 .
SF
Key:
do ~ outside diameter in inches,
SP ~ safety factor, which is 1.5 for materials with guaranteed quality,
and 1.8 for materials without guaranteed quality,
fJ ~ form factor, which is about 2 for bottoms without manhole aml
compound curve, and about 1.1 for bottoms with hemispherical shape.
The bottom is buU-joint welded to the she11, therefore, no different
wa11 thicknesses are used, and they are not made smaller than 5/16 in.
For prefi11 vessels exceeding an inside diameter of 32 in., a manhole is
provided in the bottom. An observation hole is sufficient for smaller
vessels. The water pressure test is performed with 30% over the amount
of the operating pressure.
Fig. 54 (p. 64) shows the arrangement of a prefill vessel above the
press cylinder. The filling water is fed into the cylinder via the shortest
distance; a filling pipe is not required, the flow resistances of the water
are low, resulting in the most favorable section for the prefill valve.
Disadvantageous, on the other hand, are the increased height above
floor, the inconvenient maintenance of the vessel, the elevated center
of gravity of the press, and the necessity to bleed the water and the aiI'
from the prefill vessel in case of removal of the prefill valve 01' the gaskets,
as generally no particular shut-off device is provided between prefill ves-
sel and prefill valve.
If the prefill vessel, as per fig. 106, is arranged adjacent to the forging
press, all of the afore-mentioned drawbacks may be avoided; one has
to put up, however, with increased pullback resistances due to higher
pressure in the prefill vessel to overcome the piping resistances, as well
as with a filling pipe, having the same prefill valve cross-section.
Single-frame forging presses are frequently provided with integrally-
cast prefill vesscl (fig. 59), the core holes being tightly sealed with flanges.
134 PRESSURE FLUID INSTALLATIOJl\S
As a slight displacement of the core and porous points cannot be posi-

tively avoided during casting, the frame is also frequently provided with
a cored space into which a welded vessel is inserted (fig. 61).
An immersion tube is connected to the upper flange. The eonnection
to the prefill valve is suitably effeeted by a flexible line so that no leak-
ages are caused by the breathing of the press.
The prefill valve accessories include a safety val ve, a water- or oiI
le veI gauge respeetively with a pressure gauge as well as the valves for
:Fig. 106. Stcalll-hydraulie 2,200-ton forging: press eCH1Vf'rte(\ ta <H'('l1lllUlator nperatioll.

(By: HydrauliJ" ])uh-!JIlrg.)
diseharging and eharging of fluid and air. Prefill vessels, which arc
arranged on top of the press eylinder, are also equipped with two test
eocks, to be servieed from the pulpit, for eheeking the fluid- and gas
volumes.
For shutting off the prefill vessel, if the press is to be shut down or if
repair works have to be done , on water-operated installations a shutoff
deviee (fig. 107) is arranged direetly at the filling pipe conneetion that
opens in direction of the prefill vessel, so that the water discharged from
the press cylinder may flow into the prefill vessel at any time and thus
prevents a pipe burst in the filling line. Only the opened position of the
shutoff d evicc can be locked. In order to make an opening of the shutoff
valve possible , which is loaded with the pressure of the prefill vessel,
HYDRAULIC LINE SYSTEMS 13.5
a connection has to be established first to the pressureless valve space

on the press side, by means of a small relieve valve.
Instead of this shutoff valve, a valve as per fig. 108 may be used;
it is kept open by the valve stern and acts as a check valve when it is
closed.
For oiI operation, an electrically controlled shutoff valve is arranged
in the filling line which is synchronized with the current feed for the
drive motor of the main pumps, thus avoiding a discharge of the prefill
Fig. 107. Shutoff device with relicve valve for prefil! vcssel.
vessel through leaky points in the press installation, in case of current

failure or shutdown of the press.
If a pressureless reservoir is employed, which is commonly used for
water operation and from which the high-pressure pumps are fed, an
overflow valve is arranged at the prefill vessel, which opens if the normal
water level is exceeded and allows for the excess water to flow back into
the reservoir. The excess water is attained by the amount of pressure
water which is delivered either by the accumulator or by the directly
driving pumps at each working cycle, while the amount of filling water
reciprocates between prefill vessel and press cylinder.
Fig. 109 illustrates a proven design of the overflow valve. If the
pressure of the prefill vessel in space a exceeds a certain amount, the
piston d is lifted by a crossbeam b, which is loaded by lateral springs c,
so that the overflow valve e can open through lever system f. By the
cushioned movement of piston d, a smooth opening and closing of the
overflow valve e is achieved.
136 PRESSURE 'F LVID INSTALLATIO:KS
The pressure-dependent overflow valve may also be replaced by el

float valve which responds to the water level. In this case, pressure
drops due to lost air do not cause a shifting of the overflow-tripping
water level.
Fig. 108. COlllllilH'll :;;hllto fI- alHl ehce].;: \"al\'I '. Fig. 109. OYl'rflow valve wit.JI ~ prillg-lond(' d
cll~lIjolling pi;-.;f,olJ.
2. Tanks, Coolers and Filters

On watcr-operated forging press installations, the water that has been
tLischarged irom the press or its auxiliary cylinders through the control
gear OI' from the prefill vessel through the overflow valve is dumped into
a reservoir, irom which the pumps for the direct drive of the press OI"
the feed pumps for the accumulator respectively suck the water. In order
t,o facilitate the fluid feed to the pumps, the reservoir is placed 12 to
15 feet above pump intake port. The total amount of water of the closed
water circuit is to empty into the reservoir in case of leaky valve or
shutoff device. Its working volume, therefore, is choscn V = 1.5 Vu.
if VG is the total volume of alI water-bearing installation parts. Moreover,
a large reservoir effects ample cooling of the water which is heated by
high-duty running of the press due to the throttle passages and fim,·
resistances; the water tempera ture should not exceed 85 to 105 oF.
A tank reservoir as per fig. 110 is rectangular-shaped and completely
welded. In order to increase rigidity, the two longitudinal walls are
connected by partitions with diagonally arranged cutouts in the corners
to improve water circulation. A cover plate protects the tank against.
dust.
The tank is provided with orifices for the return lines from the press,
for the suction line to the pumps, for the fresh water supply, and for the
drainage and overflow. The drainage pipe, equipped with agate valve,
is connected to the overflow line, the latter frequently being arranged
ilS a vertical pipe inside the tank.
A
r OroÎ/l
- ,.B
'HlOO
-@~
I
&c/ion A -B
Fig. 110. 'fank for 2,650 gal!. of working volume.
The supply- and pump intake lines connect to tank slightly above
bottom so that dirt and foreign matters can deposit. In order to keep the
water surface smooth, the water is fed into tank through horizontally
arranged holes in the supply line. For this purpose, a short piece of pipe
is plugged at the bottom end and provided with lateral slots. For renewal
of the water-oil emulsion, which has to be done about every one year
of operation on the average, the tank content is drained, and ~ after
the tank walls have been cleaned ~ replaced by a new emulsion which
was prepared in a mixer.
The return oiI on oil-operated presses is discharged by auxiliary
pump- or accumulator-driven pistons of auxiliary devices and control
138 PRESSURE :FLUID INSTALLATIONS
gears into a low level pressureless oiI reservoir from which it is forced
into the prefill vessel by so-called circulating pumps. AIso the oilleaking
through glands, control gears, pump pistons etc. as well as the leak oiI
at the wear surfaces is collected and fed into the oiI reservoir. The oiI
tank is sized such that it can receive the whole amount of oiI of the
installation. This also ensures a calm oiI strcam and alIows for dirt and
foreign matters to deposit on the tank bottom. Moreover, a considerable
amount of oil heat can be radiated again from the tank walIs.
For water operation, the tempera ture of the pressure fluid is limited
- with regard to the service life of the sealings, particularly the leather
sleeves - to 95 to 105 OF. Higher temperatures impair, in addition, the
stabiIity of the water-oil emulsion and expedite corrosion. For oiI a
temperature of abt. 105 to 140 OF is permissible, in order to keep aging
of the oil due to oxydation within bearable limits. Reaching and keeping
a certain operating tempcrature, however, is desirable on account of the
fluctuation of oiI viscosity with different temperatures. In oil-operated
installations, the return oiI, which is fed from the reservoir back into the
prefill vessel, is usually cooled.
The heat to be eliminated by a cooler - and t.hus the size of t.he
cooling arca - e. g. of a water cooling coil, and the required amount of
cooling water and cooling temperature, may be only roughly determined
by estimation of thc prcvailing operating conditions.
If
2"1", indicate'! the actually consurned press capacity, cxpressed by thc
average hydraulic capacity in H.P., delivered by the purnp ovcr an
extended period of tirne, e. g. a shift:
N _ QmP",-
m- 450 '
(1 - 1]J 2"1", indicates the power loss caused by the heat of the prcssurc fluid,
and which designates chiefly the throttlc and flow losses,
t.hen the capacity converted int.o heat is:
NU! = (1 - riU!) Qz;6m 632 in kcal/h.
N m = !?~'5~m is the calculated average value, taking into account

that
1. the medium fluid pressure pm for accumulator operation is to be
put equal to the nominal pressure p in the pressure fluid unit, while at.
direct drive of the press by pumps or intensifier a certain pressure will be
crea ted according to the forging resistance; in the la tter case the a verage
value of t.he required fluid pressure for single-purpose presses may bc
chosen pm = (0.9 to 1) p at.m, for multipurpose presses pm = (0.4 to 0.8)
p atm approximately;
2. the press does not operate uninterruptedly during the period of

time taken as a basis; the dead cycle time for manipulating the work-
piece, for checking the dimensions, for transport of the ingot from fur-
nace etc. may possibly take a predominant share, so that the consumed
amount of fluid Qm - depending on the forging program - is about
Qm = (0.3 to 0.7) Q dm3 /min, Q being the installed pump delivery.
The coefficient of efficiency 17w, which indicates the conversion into
heat, depends on the design of the valves, piping, etc. as well as on the
condition of the moving pump- and control gear parts which are in
contact with the fluid and is estimated to be 1]w = 0.8 to 0.9.
Part of the generated heat is radiated. This amount of radiated
heat is
Key:
O = the sum of surfaces of tank, prefill vessel, pump housings, piping, control
gears, etc. in m 2 ,
k l = the surface·heat-transfer coefficient in kcalfm 2h °C,
il tI = the mean temperature difference between the heated operating fluid
and the cooling water in °C.
The remaining difference q2 = N w - ql of the generated heat has to be

dissipated from the cooler, q2 being F ·k2 L1 t2 in kcal/h,
where
F = cooling area of the cooler in m 2 ,
°c, and
k 2 = heat transfer coefficient in kcalfm2 h
il t2 = medium temperature difference between the heated operating fluid and
the cooling water in °c.
In order to reduce on one hand the required cooling water to a

minimum amount, and, on the other hand, in case of oiI operation, have
the oii reach the desired temperature shortly after commencement of
operation, it would be suitable to switch on the cooler only after a cer-
tain period of press operation. For this purpose, the cooling water flow
may be regulated either by hand, or automatically dependant upon the
operating temperature reached.
For protection of the sliding surfaces on the press, particularly the
ground pistons of pumps and control gears of the oiI drive, the valve
seats, and the sealing points, against foreign matters and dirt, a filter
is provided which must frequently be checked and cleaned, especially
during the initial period of operation. Aiso for water operation the arrange-
ment of a filter in front of the control gears is advisable, if contamination
of the used water is anticipated.
3. Pipiug aud ShutofI Devices

For hydraulic piping seamless steel pipes are used E'xelusively. In
order to keep the pressure drop due to flow resistances as welI as wcar
and noise within bearable limits, the flow velocity of water in pressure
pipes with 3,000 psi. ancI above is chosen 26 to 33 ft.fsec. for common
piping length; for oiI not exceeding 20 to 26 ft.fsec., duc to it~ greater
viscosity. For preventing water hammer in filling pipE'~ duE' to mass
inertia of the fluid, a speed of maximum 10 to 13 ft./sec. is permissiblc
in these lines, and about 7 ft./sec. in return lincs. A calcuJation of the
pressure drop is generaIly only required for filling pipes and for long
lines with numerous elbow~, bends, distributing pieces and similar
pressure cIrop causing parts.
The caleulation for piping is performed according to thE' equation
' -Tiiv m kg;m".l)

"! 2 • ")
LI p = C
Key:
l' ~ the speeific gravity of the fluid in kgfm3 ,
1" ~ the flow velocity in m/s and
fi ~ 9.81 m/s 2 •
The coefficient of resistance c is determined by
c=c d
l
(l ~ piping length,
d ~ inside diameter of pipe),
the coefficient of friction ( may be noted from fig. 111, taking into COI1-
sideration the roughness of the pipe wall and after determinatio!l of
Reynold's number
( V ~ rate of flow in m 3/s,

d ~ inside diameter of pipe in m)
The kinematic viscosity _r~fI. may be read from table 16. Values for the
roughness of the pipe walI k s in m, which can vary within a broad range.
are given in the following list. It should be noted, however, that k s may
increase by ten times this value after an extended period of operatioTl
due to deposits at the pipe walI, and with dirty operating mcdium.
Drawn steel pipes le, (0.01 to 0.015) 10- 3 m,
~
welded steel pipes le, (0.05 to 0.1) 10- 3 m.
~
cast iron Ic, = (0.25 to 0.5) 1O-3 m .
1) Hefer to p. 1.56 for the converted formula.

o, / T T I I
0,08 ~MŢ
1- I
C1'Iţ..
turbulent
li --
_! I
I
I
I
~
I
f..- I I I
0,05
0,05 1\ :I t- I I f'OlIg~
\ rIi ~~H I
, I I I
t 'iJ-J ~~
O,Ot;. I
0,03 1- I-j'f
~m I
~~ t-- I
0,02
~
~ r--- ' I
4~ ~ H-.:
rn
I
I I :-...
I I ~ -
0,07
I ~
,rrZJ J .f
fO 4 Z J 5 1 0 ZJJ 10 6' Z J J /0~7
Re-
]<'ig. 111. Coefficients of friction of smooth and rough pipe, at laminar and turhulent flo,," (accordin!!
to MOODY).
Table 16. Specific Gravity and Kinematic Viscosity

<1
Oii,
'ro ""f
:;:.:;:
"",
\\' af er
13 \ ' )[ S Slwll
~a HTl Oii ~; '1'cilus 41
~u
kg 20° 892 90
y in - -
m3 50° 70 870
n,o:! 20° 1.006 22:1 320

1.0& ' / (f in - - 80
/' s 50° 0.,357 20 42 60
To compensate for rust and scale, k s is usually substituted by o.~~

to 2.5.10- 3 m.
For pipe components, test data as per table 17 have been compiled
for the coefficient of resistance c = C~ . For the intake from vessels.
following values according to VVEISBACH are used:
sharp-edged c ~ 0.5,
chamfered edge c ~ 0.25,
rounded edge c ~ 0.06.
For valves a factor of c = 3 to 7 is chosen, depending on the design

of the flow space. With oil-operated piston valves concerned value:>
up to c = 8 have been obtained.
142 PRESSURE FLL'ID INSTALLATIONS
Table 17. Coefficients of Friction c of Pipe Fittings

a) Angle Fitting (as per KIRCHBACH and SCHUBART)
6= 22.5 ° 30° 45° 60° 90°
C smooth 0.07 O.ll 0.24 0.47 1.13

C !'OlIgli O. l l 0.17 0.32 0.68 1.27
b) Bends (as per HOFMANN and \VASIELEWSKI)
'rId = 1
I 2
I ~
I (;
1
lI)
Csm ooth ; (j = 45°

600
0.14
0.19 I 0.09
0.12
0.0
0.10
0.075
0.09
0.Q7
0.Q7
900 0.2 1 0.14 0.11 0.09 0.11
[
Crough; (j = 90° 0.51 0.30 0.23 0. 18 0.20
o= angle of deflection,
= radius of pipe axis,
l'
d = inside diameter of pipe.
The wall thickness for pressure pipes is determined according to the

DIN-specifications and then the suitable pipe is selected from the pipe
table as per DIN!). A selection of pipes of thc most common nominal
diameters and nominal pressures is listed in table 18.
Table 18. Seamless Steel Pipes for H igh-Pl'essul'e Lines in Forging Plants at Fluctuating
Loads without Shock Loads and any other Additional Strains
Dimensions, according to DIN 2448, arc an metric
3,000 Il i. 4,500 p ' i. 6,000 1) '1.
-
.'"
--
~E
- c
'§ ~ c e
.-"'-
"-
~
'"m~ I '~"
Q~ ~ '::.8
~ .,.,
,~
~
<.>
.
~
~
.=~~~ '-'
...
Q!l'"
...,
"
~
-"
.
00
;::~ ~
.;;::; Q
:: ::
'e;, - .:.c
,...~ t.l = 3: 3E
~~ I ~~
~,
~E
~" 'Z:; "" <.>
;;;:=
.~
-:::.- 'Oi
::. ~ .~ ~,!5
::; ~ =-~
6~ ?::-E ::=
0'5 0'5 ~
- '" ~ --.;
:\w nun kgl m mm mm mm klt/m mm 111m mm kg/m
10 17,2 4 9,2 1,31 17,2 4 11,3 1 1,31 17,2 4 1,3 1

11,3 I
15 26,9 5,6 15,7 2,94 26,9 5,6 1- ,7 2,94 26,9 6,3 14,3 3,21
20 33,7 5,6 22,5 3,87 33,7 6 ,3 21,1 4,27 33,7 7,1 19,5 4,67
25 42,4 6,3 29,8 5,62 42,4 7,1 28,2 6,19 42,4 8,8 24,8 7,27
32 48,3 7,1 34,1 7,24 48,3 8 32,3 7,93 60,3 12,5 35,3 1 14,8
40 60,3 8,8 42,7 11,1 60,3 10 40,3 12,4 76,1 16 44,1 23,7
50 76,1 10 56,1 16,3 76,1 12,5 51,1 1 197 88,9 17,5 539
1 30,8
65 88,9 11 1 66,9 21,2 101,6 17,5 66,6 36,2 114,3 22,2 69,9 50,4
80 101,6 11 79,6 24,7 139,7 25 89,7 71,1 1
139,7 28 83,7 77,1
100 139,7 1751047 52,7 168,3 130 108,:~102,4 168,3 32 104,3 107,5
125 168,3 20' 1128;3 73,1 193,7 32 123,7 136, 193,7 36 121,7 139,9
1) DIN 2413, Stahlrohre, Berechnung der Wanddicke gegen Innendruck.

As material for pressures up to 6,000 psi. the steel ASTM A106 is

used, which can also safely be welded in the field. For higher pressures,
however, steels of gre ater strength are employed to decrease the wall
thickness.
:Fig. 112. Pipe conllectioll with screwcd flanges and intermediate dmin picee.
Fig. 113. Pipe cOllllcctioll with screwed bllshillg and loose flullges.
!--- -B'- ---I
:Fig. 114. Combined wclded- ami loose flange connection for pipes.
The radius of the pipe bend should be as large as possible. The inside
radius of the bend is usually chosen r ~ 5 do, do being the outside dia-
meter of the pipe. Commercial weld elbows are used for the return pipes.
The pipes are installed in ducts and positively secured so that they cannot
come loose in case of hammer. If one accumulator supplies pressure
water to several forging presses, it would be advisable to connect the
control gears to ring mains in order to avoid any extended shutdown if
one pipe bursts. This pipe connection would usually be closed by a
blind flange.
144 PRESSURE 'FLUID INSTALLATIONS
In former times screwed flanges as per fig. 112 were used predomi-
nantly for pipe connections. Their disadvantage was, however, that the
pipes were frequently ruptured in the thread directly behind the flange.
A better design is illustrated in fig. 113, where the pipe ends are provided
with threaded co11ars which are tightened together by loose flanges. Thc
most common pipe connection with weld colI ars employed nowadays is
shown in fig. 114,~which requires, however, careful welding by reliahlc
and authorized welders. Table 19 lists dimensions of such pipe connec-
tions for nominal pressures of 3,000, 4,500 and 6,000 psi. Weld collars are
usually made of steel ASTM A 7, flanges of steel ASTM A 7 or HR lO20.
and bolts of Steel ASTM A261GR 80. Flanges which are not carrieei
out with standard dimensions have to be calculated. A round shape i"
chosen for flange connections exceeding 5 in. nominal diameter so that a
larger number of flange bolts may be arranged with regard to eaR.\'
tightening of the bolts.
The seals are made of copper. Lens-shaped seals of soft iron, similar
to DIN 2696, have also given very good results. For draining of the
piping drain screws have to be provided at the lowest points of the
piping system (see fig. 43, p. 54), which are either housed in socket8
welded to the pipes or arranged between the flanges in special drain
pieces (fig. 112).
For pipe connections in feed- and return lines as weU as at accessorie8
and control gears weld flanges are lIsed (fig. 115). The nominal pressurc
,Fig . 115. Wcld tlang c for fee(1- and re!uJ'Jllin(''',
is ehosen pn = 150 psi. for return lines leading to the elevated tank, and
350 psi. for sueh lines which are subject to air vessel pressure. While the
walI thieknesses of the pipes for both nominal pressures show no differ-
ence, the dimensions for the pipe connections as per DIN 2632 and
DIN 2634 vary (see table 20). The material for the gaskets is rubber with
plies of fabric.
As a rule, aceessories of the piping system consist of distributing
pieees, high-pressure shutoff devices, gate-type shutoff valves, shutters.
and three-way eocks.
Table 19. Dimensions for Pipe Connections as per fig. 114

(Dimensions in mm)
...."
",î" l'il
ta!,,1 " 1 I er Flnngc
DIX 260i
W elding
neck Ilang G"skct Bol\<;
DIX 2 13
:§ă. DIX 2 10
t~ -
;;:...:-::
o;. d B 8, d, d. I d, d, I, b di I d. I '. el, Il
4 22
29
95
15
15
20,5
Il 'M16
16
110
110
34 19 25,5 / 2.5 ~'ll6 120
39 24 30,5 M16 120
t
! 50 33 39 i\'I20 140
o
g 61 42 51 r[ 24 160
'" 6 49
71
5
82 J
1.130
M30
190
200
7 102 36 x 3 260
105 120 \4 142x 3 300
129 144 1
ll14 x 3 360
9,5 15 M 16 110
15
19
24
20,5
25,5
30,5
)2,' M16
1\U6
M20
110
120
140
"[
o
34,5 435 M24 160
o 39 4 M30 190
'"....' 50
73
61
6
3
t M30
I36 x 3
190
260
7
1O~
102
120 ), i\'I42 x 3
i\'I 8x 3
300
3 O
129 144 M56 x 4 400
9,5
16
15 1
22, ~ f 2,5
fI6
16
110
120
24 30,5 M20 140
<F.
2 M24 160
1
Q.
8o 34,5 43,5 3 ~130 190

<.5 42 35
51 130 190
~4
65 M36 x 3 260
73 6 M42 x 3 300
5 100 \ 4 M4 x 3 360
105 120 400
I
~156 x 4
129 144 M64 x 4 440
3,000 II I. 6,000 psl.
d6 - di) + O 5 fim up to l\' W 25 lip to }.'"\V 25 lip to l\'IV 20

d6 = db + 1 mm above and includ ing above and inclllcling above and including
NW 32 N \\ 32 K\V 25
It = 5 mlll up to l\TW 25 up to N\V 25 up to XW 20
It - 6 mm for J\V 32 up o fol' 1"-\ 32 up to fol' N'" 25 up to
NW 6 :N' 50 J.:J\V 50
li = mm for }HV O lip to for N \\ 65 up to for ~\V 6.- up to
r \ \ 125 ~\, 125 ~\Y 125
10 Miiller, H,"draulic FOl'ging l'n'",,'s
146 PltESSl:ltE FLLID INSTALLATIONS
The distributing pieces for the pressure lines arc simple pieces of
forged steel AISI 1035 with bored channels. They should preferably
be mounted such that the piping ean be drained by removing a plug.
For the return Iines weld fittings are employed; in simple cases, however,
the branch line is welded directly to the main line.
Generally, high-pressure shutoff devices (figs. 116 to 118) are installed
only in pipe systems which are connected to an accumulator. They are
required to enable repair works at the press or at the piping also if the
accumulator is charged. In case of a central supply of several presses
the shutoff devices are such arranged that the accumulator as well as the
individual presses can be shut down.
Table 20. Dirnensions of Pipes and Flanges as per fig. 115 and in accordancc with
German Standards DIN 2632 to 2635
(AII dimensions in mm)
1 J( Nominal p rc;;"lI rc 140 IlS;' NOIoioa l ! lrCSSu rc 350 p.i.
- -- -
Pi lle l'illC Flnngc Bolt.
_.
}"Ian g
- -- - - Boit"
.. . .... ZI '"
I .o..o .ci ..
.e ;lj
. ."
<>
..,,,~
1;
~ CI-!
.-!J E" I -.., "
== ~
.= o .=!;: '"<=
0'-'
<0- '"'"<=w Ş 1:: ." "E
'-..- -e
<.>
.- "§
" d ."
§~
.:::: Q ,;..:.
.!i = - ,,.:;.:: - -" .:: ~ E -"
~
'O" '"
..>ţ; ţ;
- u .>!
p." o.:::
'Z
. ~ ':::
6:5 >--- ].~
:l e d._ d Q
'""
~:;; .c ~=
o~ ţ:: ::: ~ ~ A F.
,.... 1=:
.vw """"' I ~ ~ :-"1 - :
a 8 a I 8 D b
" " 1 D b
" k l
15 20 2 95 14 35 65 4 2 1,3 2 14 95 16 38 65 4 14
20 25 2 105 16 38 75 4 26,9 2,3 14 105 18 40 75 4 14
25
32
30
38
2,5
2,5
115 16
140 16
85 4
100 4
33,7
42,4
2,6
2,6 :g 14 115
18 140
18
18
40
42
85 4 14
100 4 1
40 44,5 2,5 150 16 42 HO 4 48,3 2,6 18 150 18 45 110 4 18
50 57 3 165 18 45 125 460,3 2,9 18 165 20 48 125 4 18
65 76, 1 29 185 18 45 145 476,1 2,9 18 185 22 52 145 8 1
80 88,9 3,2 200 20 50 160 488,9 3,2 18 200 24 58 160 8 1
100 108 4 114,3
220 20 52 180 8 3,6 18 235 24 65 190 8 23
125 133 4 139,7
250 22 55 210 8 4 18 270 26 68 220 8 27
150 159 4,5 168,3
2 5 22 55 240 8 4,5 23 300 28 75 250 8 27
200 216 6 219,1
340 24 62 295 12 5,9 23 360 30 80 310 12 27
250 267 7 273
405 26 70 355 12 6,3 27 425 32 88 370 12 30
:
300 318 8 323,9
7,1 460 28 78 410 12 27 485 34 92 430 16 30
1 As far as stiH being produced.
II Standard dimensions as per DIN 2448.
The shutofl' valve is arranged in a forged housing of steel AISI 1035.

Un the larger types the valve and the valve stern are relieved (see figs. 117
and 118). The materials for the intern al components are choscn in
accordance with the specifications on p.158. Dimensions for high-pressure
Fig. 116. High·prcssure shutoff valve for small nominal diamctcrs with unrclieyctl yalve ,tem and
built·ill relief valvc.
} ' jt! . 1 18 . .I-li ~ll · llre ~ ~;u r ~ hutolr ntl\'c wilh T"l'lic, -(·d \-ah' tC' I U
allcl witll relit..' r IJY JIl€;'ans of 1,y·pal--!"o \"aln '.
J'ig. ll7. High·prcssnre shuto(f val ve wHh rrlievrd val vc ste m an,1 built·iu relidval\"c.
10*
148 CONTROLS FOR FORCING PHESSES
shutoff valves Up to 11/ 2 in. intern al diameter with unrelieved valve

stem are listed in table 21.
Table 21. Dimension8 (~l High-Prc88ure Shutoff Valvcs as per fig. 116
(AU dimensions in mm)
J ,OOO JI"i. O.OUO Il'i.
" I
"
J) )l l- b c a
I
It
I d b c
10/ 12
16
18
160
190
230
163
162
173
12
12
14
I 18
20
22
80
90
100
52
58
64
15
15
]8
22
24
28
80
94
115
52
58
70
15
18
22
25 230 204 14 22 lOO 64 18 28 115 70 22
I I
32 280 208 14 26 115 74 22 32 140 84 28
40 320 240 14 30 l:i5 90 I 2n 40 160 100 32
The use of gate-type shutoff valves is permitted only in those re turn

lines where the fluid flows in one direction only, e. g. in pump suction
lines, otherwise, in case of the valve being closed accidentally, the return
devices would create an unpermissible high pressure in the pipes. There-
fore, the gate-type shutoff valves are seldom employed and replaced by
shutters - in the feed pipes - as per fig. 107; or also by three-way
cocks in the control gear return line. Three-way cocks may bc suitably
applied only in pipes up to abt. 3 in. internal diameter; they are usually
arranged directly behind each control gear. They offer the advantage
that for minor repairs, e. g. packing of a stuffing box, replacing of the
lift rods or the drain valves in control gears, the return line can be
simultaneously shut off against the elevated tank, and the water from
the cylinders, the control gears and piping may be drained.
Chapter III
CONTROLS FOR FORGING PRESSES

a) Control Gears
The required gear for controlling the prcss ram movement and the
movements of the auxiliary equipment consists of thc control poppct
valves or the control slide valves, their drive, and the equipmcnt for the
proper successive valve movements. The control gear determines the
working stroke of the press by the opening and closing of the poppet 01'
slide valves which control the feed and return of the cylinder's fluid.
It consists of the main control gear for the operation of the press ram
and its re turn and the control gear for the cxisting auxiliary clevices such
as shifting table , lateral die slide , ejecting device, pulJey, etc . As occasioll
CONTROL GEARS 149
demands, a selector control gear is provided for the various power stages
of a multiple-cylinder press, or for chosing a second pressure stage
which is generated by a pressure intensifier; and finally pilot or servo
controls for hydraulically actuating gears which require large operating
forces.
For both the advance and return motions of w hydraulic ram drive,
inlet and outlet valves are usually required which are combined in Il
four-valve control gear and are actuated together. If, however, a con-
stant force on the retum piston area, retum spring, or the weight of the
moving parts can be taken into account for the retum device, it would
be sufficient to only control the inlet and outlet for the advanced motion
and to employ a two-way valve control gear. Aiso control gear
used only for reversing the direction of flow require only one pair of
valves.
As a rule, forging presses are to carry out cogging and upsetting
operations with large working strokes, as well as planishing operations
with small penetration depth and many successive strokes which influencc
the control gear design.
In a working cycle for long-stroke forging operations the main con-
trol gear has to bring about:
1. The idle motion of the press until contacting the workpiece. This
stroke is effected by the accumulator - in order to save the high-pressure
fluid - or, if the direct pump drive is concemed, by the low pressure
from the air vessel to attain a satisfying velocity (control positioll
"advance").
2. The working stroke, carried out by the high-pressure fluid in
the prefill tank with regulable speed by throttling 01' - in case of
direct pump drive - with the speed given by the pumps and a fluid
pressure resulting from the forging resistance (control position "full
load").
3. The return, by means of high pressure from the accumulator or
by the pumps respectively if direct pump drive is concemed, the volume
of the press cylinder being discharged against the aiI' vessel pre8sure and
the moving weightsbeing lifted (control position "retum").
4. Stopping of the press in any position, with - depending upon the
kind of control- the weights of the movable components or, in addition,
the press plunger exposed to the air vessel pressure resting against the
fluid trapped in the retum cylinders, or the retum rams pushing against
the fluid trapped in the press cylinder (control position "stop").
For short strokes (planishing) with only minor idle motions the usc
of low-pressure fluid from the air vessel has been abolished for attaining
a fast stroke sequence, and the movements in both directions are carrica
out by the existing high-pressure source.
150 CONTROLS FOR FORGING PRESSES
Thercfore, thc working cycle demandR the follmving control posi-

tions:
1. Stand-stiH in any position,
2. Full pressure for idle and working strokes,
3. Return, like the afore-mentioned re turn for long-stroke forging
operations.
Frequently the return cylinders are subjected to high pressurc also
during the down motion of the press ram, thus decreasing the dead cyclc
time.
The features of the control gear for the described operation cyclc
of a plunger are schematicaIly illustrated for accumulator operation in
fig. 119. Opening and closing of valves 1 to 4, which are actuated by a
common rocker shaft, is shown in the valve lift diagram, by which the
valve motions in the operating range of the controllcver can be trailed.
Va/VI? lifl tliogrom

I JI JJl JI!
Fig. 119. Sclwlllaticai illustration of a four-way valve contrul geal' for an accunmlator-ojlcmtcd Jln'''.
In the iHustrated position III (stand-stiH) the working plunger is

subjected to the air vessel pressure, the fluid in the pUIlbacks, however,
is trapped due to the closed valve 2, thus maintaining the momentary
position of the working plunger, In position II (advance) thc air vesscl
pressure causes a lift of valve 4 through which the low-pressurc flnicl.
flows into the cylinder while the fluid from the return cylinders is drained
into the air vessel through the open valve 2. In the forc-most position 1
(full load) the high-pressure fluid enters the cylinder through valvc 3
now being open while valve 4 is closed. On retracting the hand lever,
the positions II and 111 are successively contacted again and in posi-
tion IV (return) high-pressure fluid is fed into the return cylinders
- through the open valve 1 - which for ce the plunger upward and drain
the working cylinder into the aiI' vessel through valve 4.
Rach of the positions 1 to IV extends over a certain range, but most
commonly only the click-stop locations are designated which ensure thc
most favorable valve opening for the respective range.
CONTROL GEARS 151
For easy understanding of the hydraulic circuit diagrams for the

various press installations the chosen designation I to IV of the control
positions and the designation of the valves are maintened, where
1 = inlet \ 3 = inlet }
2 = outlet f return 4 = outlet advance.
When using the commonly adapted symbols for hydraulic compo-

nents 1 ), no matter whether poppet or slide valves are concerned, the
diagram as per fig. 120 is obtained for the same controls.
Fig. 120. Schemat.ical illustration as per fig. 119 using the commonly adapt.ed symbols for hydraulie
cOJnponents.
In case of using a slide valve instead of poppet valves, a four-way

valve control gear is replaced by a four-way slide valve, the functions
of which for the individual positions may be noted from fig. 121. The
schematic illustration is based on the direct pump drive of a press.
Fjg. 121. 'Yorking diagrml1 of a four-\vay slidr valye for faur control positiollS.
In most cases, however, it is not feasible to provide equal ilow openings

for the four ways to be controlled and to arrange them in one slide valvc.
Therefore, the slide valve controls are subdivided into two or several
1) VDMA.EinheitsbIătter, K61n: Beuth.Vertrieb.
152 CONTROLS FOR FORGlNG PRESSES
slide valves of the required different size, their pistons being actuated by
a common drive analogous to the rocker shaft for valve control gears.
1 Elevafed /oni
Air
OI/Cd/QWn
va/ve ..-
-
vesse/
I
Ifccumu/olor
Valve IIR diogrom
~~~A
J![ .lY
I II I
\ \ I
~
\\ I
\
=
1:: {I ForgilllJ
~ Con/rollever J[ Adl/ollce
~ plN/liO!1S 1Il Stop
lI! Relur/!
Fig. 122. VaIYC' control gr-ar "'itlt prdm yal\"f' for tI\(' lllaill eout-rob of au acculIlulator-operah'd
forgillg l-lre~~.
The poppet and slide valves used for steam engines are also employecl
for steam- and air-hydraulic presses.
Due to occasional special requirements for press operation and depend-
ing upon the kind of drive, deviations from thc described basic design
of a main control gear 01' additions to it might arise. These are described
in detail hereafter, as well as the design of the controls for auxiliary
equipment, 01' selector controls, and the pilot and servo controls.
The required ftow area of a valve depends upon t.he ftow velocity
which in t.urn is governed by t.he velocity head available. Ample veloc-
ity heads are available for the inlet valves 1 and 3 and the drain valve 2
(see fig. 119). On the other hand, very unfavorable conditions exist with
drain valve 4: - the velocit.y of the press ram upon lowering is to be as
CONTROL GEARS 153
high as possible. But the filling of the press cylinder is dependent on the
low air vessel pressure. For this reason valve 4 is provided with a very
:Fig. 12:1. Fillill!( valve with push-rod Fig. 124. );'illing valve with built-iu
aud spring retul'n. relief valve.
large cross-sectional area as compared with the other valves and, therefore,
it would not be feasible to arrange this valve in a common valve housing.
On account of these facts a different design of the main control gear,
as compared with fig. 119, is chosen and the drain valve, which is
analogously called "filling valve", is separated from the other valves

and arranged directly at the press cylinder (fig. 122). The additional
feature of this arrangement is the fact that a thick-wall high-pressure
pipe between valve hou 'ing and cylinde1',
hav:ing a flow diameter equal to the fillina
alve i eliminated,
As this fi)]jng val ve i ' no 10nO'e1' actuated
by the control haft, it i forced open by a
pu h-rod (fig. 123) which i s, in imple cases,
harged with tbe return cylind r fluid
imu]tal1 ously.
In order to prevent tbe filling va.lve from
being opened by the pu h -rod against the
pr ur water, a mall relief valve 4 i"
maintain ed in the valve block wruch open
prior to the retw'n motiol1 and l' Ueves the
pre sure in th pres cylinder.
Tbe pres ure may also be relieved irom
the pres cylinder by a rranging a pre-opening
va lve in the prefill valve a
per fia, 124 ; this de ign, ho\\'-
ever, i eldom employed.
Tbc mode of operation of
Htgh-prc.rsur& t he controls is not cha naed
wukrinluke by arra nging a fillina valve
epamtcly, The control e-
guence i iJ lustratcd by t he hydra ulic circuit
d iaaram a per fig, 122 for an accumulator-
op rated one-cylinder pre s. While the pre s
l'am i8 beinO' advanced, th fillin a water fiow
into the pres cylinder by lifting the fUJina
alve. A oon a t be retnrn cylinder are
charaed with pr sure water, the drivin a rod,
u bjectecl to pressnre imulta,neously, opens
Ji'i!.(, 125. Press cylindcr wit}t aif the filling valve , shortly aiter the pressure
vessc1 a nd built-in fllling va1\'e.
(By: Banlling, Hamm .) in the press cylinder has been relievecl by
valve 4,
There are clifferent designs for the prefill valve, It is cither arranged in
a separate housing as per fig . 123 or directly buiIt into the cylinder bot-
tom as per fig, 125. The valve housing of the design as per fig. 123 js
macle either of cast steel or of forged steel (AI SI 1035). The forged hous-
ing is usually employed jf high pressures are concerned. The valve disk
and the valve seat are made of high-duty bronze or stainless steel. For
CONTROL GEARS 155
large sizes the valve core and valve guide may be made of cast iron or
bronze of minor quality. Valve seat and cover flange in the housing are
sealed by gaskets of vulcanized fiber or by leather sleeves.
A spring retracted push-rod
opens the prefill val ve. The force
created by the pre-tensioned
spring must overcome the sleeve
friction and the hydraulic counter-
force in the working cylinder.
The design force of the push-
rod is such that the spring load
and the load on the prefill valve
are overcome which are caused
by the drain water pressure
in the press cylinder produced
by the return device. The fric-
tion losses are compensated for
by ample piston cross-sectional
area.
If using steam or compressed
air of usually about 120 to
170 psi. the piston force is trans-
mitted to a push-rod by means
of a lever to obviate a large push-
rod diameter.
fiI/ing ",aleI' inlu!re
The idea of the prefill valve
Fig. 126. J,'illing valve with positively contralI,,']
design as per fig. 126 was to pressure water intake.
prevent the pressure water flow
into the press cylinder before the filling water is shut off by the bore c.
Thus overflow losses should be eliminated in case the filling valve does
not close properly.
Upon closing of the valve the pressure water flows through bore a
behind the piston of the diameter d l ; the filling valve b is being advanced
until it closes the bore c. Sealing is effected by a packing ring. At the
same time the shoulder e hits a stop ring, thus opening valve j, until the
prefill valve is seated and the pressure water flows through the bores g
into the cylinder. The valve opens as soon as the high-pressure feed line
is drained by means of the control gear. Therefore, part of the pressure
water in the press cylinder drains through bores g and valve j, thus
relieving the press cylinder and the filling valve cylinder of diameter d1
from pressure. Subsequently the prefill valve is lifted by the constant
pressure on the annulus of the diameters dl and d2 and enables drainage
through bore c.
The size of the filling valve fio\\' are a is dependent on the recluir('d
lowering speed of the press ram:
A v= AR'VR
in which
AR ~ area of the press ram,
v R ~ Iowering 8peed,
A ~ ftow area at valve seat if the valve is fully open,
v ~ flow velocity at valve seat.
In most cases a lowering speed of VR = 12 to 16 in.jsec. meets alI
forging requirements, the higher values applying to small and medium-
size presses. The fiow velocity v in the filling valve should not be chosen
higher than 20 to 26 ft.jsec., in order to keep the air vessel pressure -
which is required to overcome the fiow resistances - in bearable limits.
This results in the frequently employed rule of thumb for de::;ign:
A = 0.05 AR
or v = 20 VR respectively.
For computation, the pressure drop L1 p in the filling valve iti determined
hy the equntiol1: r Î' 'L. 2
J p = 62.355 2 9 in lbs.jsq. ft.
• C Î' L'Z. .'. •
or J p = 0.433 29 m lbs.,sq. m.
'\vith
y ~ specific gravity of the fluid in Ib8. Ieu. ft.
t' ~ flow velocity in the prefill yalve in ft.jscc ..
9~ 32.16 ft.jsec. 2 •
The coefficient of resistance citi obtnined by tcst readings on existing
valves 1 ) and may approximately be ChOSC11 c = 5 for a prefill valve
including the connecting pipe bend" nnd the short feed line.
The advnntnges of the prefill valve - saving of high-prestiure flui(l
if accumulator operation is eoncemeel. or increase of the lowcring spee(l
in case of dircct pump drive - become greater the longer the required
idle stroke. Considerable idle strokes occur, e.g., aiter shifting OI' rotat-
ing of the workpiece and at long cogging strokes, while planishing opera-
tions require no idle strokes worth mentioning due to the low penctration
depth. On the other hand, the dead cycle time is considerahly increased
in case of very short strokes. The elend cycle time iti composed, arnong8t
others, of the time required to buileI up the full operating pressure in the
cylinder to actunte the prefill vnlve.
A control gear enabling forging operations with prefill val ve as well
as planishing operations - as described above - may be differently
1) DUBBELS Taschenbuch fiir den Maschinenbau, Bd. 1, ] 2. Aufl., 2. beJ'. Xeudr.,
BerlinjHeidelbergjXew York: Springer 1966, p. 790.
CONTROL GEARS 157
designed. The control gear as per fig. 127 has been supplemented by the
valves 5 and 6 which control the push-rod for the filling valve. This
brings about the advantage - for large-stroke operations - that open-
ing of the prefill valve can be effected shortly prior to the return motion.
Moreover, a reversing valve is arranged in the return line that keeps the
!ofili! ~pl1sh-rod
pl1l/b-aclr""'s~;':;:;--=;v
#ain control flear

1 II 1lI .IY
Fi~. 127. Su!,plemented control genr for controlled filling vnlve ami ren'rsal to constant rcturllioad
for planishing.
discharge valve for the return cylinders continuously open when planish-
ing, but actuates, however, the valves 1 and 2 of the main control gear
when cogging. Furthermore, when planishing operations are concerned.
the swing of the control lever is limited by the positions "forging" and
"standing", in order to prevent opening of valve 5.
The flow area of valve 4, which now not only serves for relieving thc
pressure in the press cylinder, has to be determined from the required
return speed and the pressure head available, The pressure for dis-
charging the press cylinder is generated by the return load, decreased
by the moving weights and their frictional resistances.
With the help of the planishing control gear 100 to 120 planishing
strokes can be performed, whereas the main control gear - which i"
designed for normal forging operations only - permits about 40 to
60 planishing strokes per minute, only utilizing approximately 0.400
to 0.600 in. of the prefill valve stroke for reducing the impact of the
prefill valve on its seat.
158 CONTROLS FOR FORGING PRESSF;S
The control valves for the various working motions are usually
actuated by a common control shaft through levers or cams, in order
to attain a motion of the valve lifting rods as per tne lift diagram. The
valves are suitably arranged in a common housing.
l!'ig. 128. Control gearwith ~ervo-nlOtor drivc for an aetulllu1ator-opt~rated forgillg 1l1'l'SS.
(By: Hytlraulik, DuiBlmrg.)
The val ve housing is made of a forged steel block (AISI 10:35) in

which alI valve chambers and channels are bored (figs. 128 and 129). The
internal components of the housing are made of high-duty forgcd bronze.
Also a hard stainless steel is used for valves, lift rods, and valve springs.
The valvc guide bushings are calculated as a holIow cylinder for external
pressure, the permissible nominal stress being 8 = 15,000 to 18,000 psi.
For valve seats - which are in most cases chamfcred at a 45° anglc -
a bearing pressure of p = 12,000 to 15,000 psi. is permissible. The fine
threads of the screwed components are calculated for shear, with the
permissible shearing stress being 8 = 3,000 to 3,750 psi. The intcrnal
components of thc valve housing are sealed by rings of vulcanized fiber.
Little air vent screws are placed where air pockets may fornI.
The valves must be properly guided. The length of the guide surface
ii; made h ~ d. The diameter clearancc between valve and guide iR
about 0.004 in. Valves up to 0.600 in. diamctcr can still be opencd manu-
alIy against 3,000 psi. by means of the lift rod. If larger diameters are
eoneerned, a smalI relief valve is provided for dcereasing the re:-;i:-;tance
when opening the control valve.
CONTROL GEARS 159
Fig. 130 illustrates a relieved hydraulic control valve. Opening

against pressure is effected by a lift rod a, which first lifts the relief
valve b slightly, thus causing a pressure drop in the relief space above the
main valve c and enabling easy opening of the main valve. In order to
Fig. 129. Cross-section through the inlct aIld outIet valve of a hydraulic control gear with througl, -
lift rods for the valves_ a Screwed valvc holder ; b Valve housing; c U cliefvalvc; d Inlet valve; e Acel!-
mulator connection ; f Lift rod; (/ Drain water connection; II Drain water space; i Outlet valve; k Con-
troIIed pressurechamber; 1 Cylinder.connection; m Pressure water ehamber; n l'aeking ring; o GIand
ring; p Screwed packing ring hOlder; q Valve scat. (By: Schloemann, DiisscIdorf.)
prevent a self-acting opening of the main valve due to underpressure in

the relief space, care must be taken that enough water from the supply
bore can flow into the chamber above the valve - through a small bore
of about 0.080 in. diameter, plus the cross-sectional area of the clearance
between valve and guide - as is required for keeping the valve seated.
Thus the main valve c must float which can be achieved by the proper
size of bores d. If the area of these bores, including the clearance
160 CONTROLS FOR FORGING PRESS ES
between val ve and guide, is too small, the valve opens by itself and
frequently a howling noise or chattering in the valve scats arc noticed,
, I
, I
}'ig.130, Killglc-l'eJj('\wl "Fig. 1:11. Yalye <.iriYt' wjth Tr U\'\"L'\l

- ('onll'ol yaly e . liftillg rod.
CONTROL GEARS 161
caused by the continuous reciprocating motions of the main valve

between the seat of the main valve and the lifted relief valve. If, however,
the are a of the bores d is too large, too much force is needed to opell
valve c. The small area of the bores d, on the other hand, entails that the
main valve c cannot act as a check
valve. Therefore, for this purpose
only unrelieved valves may be
suitably employed.
It is safe to firmly connect the
lift rods to the rocker shaft (fig. 131)
to ensure a positive retraction,
otherwise it might easily happen
that the valve rod seizes due to
friction in the packing rings and thus
prevents a closing of the val ve. This
may cause unfavorable fiows and
pressure water drops. The clearance
between lift rod and relief valve is
adjusted according to the valve lift
diagram. The correct valve stroke is
measured with the help of a thin rod
by which the relief valve is scaned
through the air vent bore.
If a pressure inlet valve is open,
the hydraulic pressure rests on the
lift rod. This load is transmitted to
the rocker shaft and the hand-lever
which, therefore, has to be locked in
its stop locations by a latch; unless
a balancing rod is provided on the
opposite shaft side, being of the Fig. 132. Double-rclicved control valve.
same diameter like the lift rod, thus
balancing the control shaft and ensuring easy handling. This balancing
rod is, however, not required for outlet valves, as the drain water
pressure exerts only negligable forces on the rocker shaft.
Fig. 132 illustrates a control valve with double relief which is employ-
ed where larger diameters and higher operating pressures are concerned.
First, the lift rod a opens the small pilot control valve b, thus relieving
chamber c and ensuring easy lifting of relief valve d. The main valve I is
opened, when valve d hits the screwed member in valve 1, after the
pressure in chamber g has dropped. A self-acting opening of valve I is
obviated again by a certain area of the holes h establishing a passage
from the relief chambers c and g to the pressure chamber. For sealing
Il )Tiiller, Hyllraulic }'orging Presscs
162 CONTROLS FOR };'ORGING PRESSES
of the top part of large valves - deviating from fig. 130 - a thrust
plate i with screw k is frequently employed to ensure better tightenillg
of the sealing ring l.
Fig. 133 shows a control valve where the lift rod for the relief valve
has been extended towards the bottom and forms a differential piston.
Through a small bore a the pressure water can pass from thc relief
chamber b into the cylinder chamber c and act on the differential piston,
thus balancing to a large extent the pressure on the relief valve; so a
second relief valve would no longer be required. The large diameter of
the differential piston equals the inside diameter of the relief valve
seat. Consequently, the closed relief valve is subjected to the following
loads: the spring load and the fuIl fluid pressure on the valve body
from above, and the fuU fluid pressure on the annulus are a of the
differelltial piston from underneath. For lifting, therefore, only a small
force is required. The control valve is relatively expensivc due to
most accurate machining. Especially the center bores must be exactly
aligned, otherwise the relief valve is not completely tight. Moreover,
a positive retraction of the lift rod - when being actuated - is not
possible.
Fig. 134 shows a control valve where the lift rod for the relief val ve
is arranged in the valve housing, protruding at the top and bottom sides
of the relief valve with equal diameters. Consequently, the lift rod is
eompletely relieved after opening the relief valve, thus rendering super-
fiuous the balancing rods for the pressure inlet valves as illustrated in
fig. 131. The closing pressure for the relief valve acts on an annulus arca
of the diameters of the onter valve seat and the lift rod in the packing
ring. Futhermore, there is the external spring load which has ta be
relatively high and which is dissipated largely by the packing ring fric-
tion. This valve, too, requires most ac curate machining and exact align-
ment of an bores if it is to clase tightly. The lift rod is rather cxpensivc
and cannot bc positively retracted either. The advantage, on the other
hand, Îs the valve adjustment, as the valve stroke can be measured
Irom the spring stud.
Frequently, pressure inlet valves are carried out - as per figs. 133
and 134 - with several rows of holes in the valve guide bushes, which are
successively cleared upon opening of the valve. The ram velocity can
thus easily be varied and the press slowly be advanced. A relatively
large valve stroke and a corresponding swing of the control shaft,
however, have to be put up ,,,ith.
The flow areas of the control valves are to be sized such that the
pressure drop resulting from ftow resistance does not exceed the bcarable
limits and that wear of valves duc ta ccccssivcly high fio\\' velocity i"
not anticipateel.
CONTROL GEARS 163
Experience has proved that a flow velocity up to 60 and 90 ft./sec.

respectively is permissible, based on the common operating pressures
Fig. lT~. ltelief valvc with extendcd lift rod Fig. 134. Relief valvc with pass-throup;h
aud J:>aek-prrH~ure differcntial piston. lift rod.
for inlet valves of 3,000 to 4,500 psi. Frequently, therefore, the inlet
valves for these pressures are determined by the rule of thumb:
v = 0.023 P ft./sec. (p = operating pressure in psi.).

11*
With reganl to flow velocity V the valve flow arca A is calculated

by the equation:
with
A K = the working area of the piston and
vK = the piston velocity required.
Based on the flow veloeity v the pressure drop LI p m a valve ]:-:
computed by the equation
L1 p = 62.355 c;;~ in lbs.!sq. H.
or L1 p = 0.433 Ci;2 in lbs./sq. in .

with
y = specific gravity of the fluid in lbs.!cu. ft.
v = flow velocity in the control valve in ft.fRec.,
g = 32.16 ft.jsec. 2 •
The coefficient of resistance c depends largely on the valve design and is

determined from readings on existing valves 1 ). For the common control
valves whieh are arranged together in one valve bloek, jncluding the:
intereonneeting straight bores, c lies in most eases between 3 and 7.
Outlet valves for whieh only a small pressure head i8 available, are
to be provided with a relatively large flow area in order not to exceeu
the permissible drop in pressure for the required amount of fluid.
The standard pipe diameter for short, straight eonneeting lines i8
chosen close to the valve diameter. Pipes, for whieh a larger diametel"
has been ealeulated, are reduced to the valve diameteL at the valvC'
bloek.
The required maximum stroke of the relief valve is to be ueterminc(l
from the annulus between lift rod and valve seat aud is mmally betwecn
0.080 and 0.160 in. The stroke of the lift rod is eomposeu of the baek-
lash up to the relief valve, the stroke of the relief valve and the mail!
valve and is shown in the valve lift diagram.
The lift rod diameter in the valve seat, is ehosen about 0.320 to
0.360 in. and in the guide bushing about 0.550 to 0.600 in. for manually
operated valves. If valves are eoncerned whieh arc aetuated by a COll-
trol mechanism, the lift rod has to be sized according to the possible
force of the control meehanism and is, as a rule, 0.630 to 0.7l0in. in thc
valve seat and about 0.790 in. in the guide bushing. For sealing, vulcan-
ized paeking rings with plies of fahrie are employed, whieh are available
in different shapes, having a packing width of about 0.:320 in. (sec fig. 130).
1) DUBBELS Taschenbuch fiir deu ;\Iaschinenbau, Bo. 1, 12. Aufl.. 2. bcr. ~euor.,
Berlin!Hcidclberg!New York: Springer 1966, p. 790.
CONTROL G EARS 165
The lift rods may be suitably connected to the rocker shaft by a pivoted
pin with adjustable length for adjusting the valve stroke.
Occasionally a cam drive is employed for lifting the control valves.
It may be carried out for reciprocating as well as for rotating motions.
In the latter case the controls may be shifted from "full pressure" to
"return" directly, without hitting the intermediate positions "advance"
and "stop". Cam drives, however, permit no positive retraction of the
Control paflet
willl
conloclllf' eqllipmenl
.....
PI
.....
PIS
...........
RO ROS
InIedod diogrom
Fig. 135. Electro·hydraulic lift urive for valve controls. 1'1 Press inlet valve; PIS l'ress·inlet·slow
auvance; RO Return outlet valve; ROS Return·outlet-slow auvance; RI Return inlet valve;
RIS Return inlct-slow Tetraction. (By: Schloemann, Diisseldorf.)
raised lift rod. In order to avoid the possibility of the lift rod getting
stuck by the packing friction, particularly strong valve closing springs
must be employed. Moreover, the cam drive requires especially careful
guiding to obviate seizure due to the large lateral forces.
Instead of a common valve drive of a main control by means of a
rocker or cam shaft, fig. 135 iIlustrates a main control with individually
actuated valves, which are provided with electro-hydraulical lifting
devices (fig. 136) where each lift rod is solenoid-controlled. In order to
avoid overlapping of valves and to ensure automatic sequence of inlet
and outlet valve motions, an interlocking means of the respective
lifting deviees has been provided in the oil-hydraulic circuit. The pic-
tured control gear is equipped with two valves each for press cylinder
inlet, return inlet, and return outlet in order to attain two different
speeds for an motions. By hand-Iever and through a relay the solenoids
of the individual lifting devices are energized for the various control
positions.
The center distance between lift rod and rocker shaft of the rocker
shaft drive as per fig. 131 is 1.180 to 2 in. A hand-Ievcr lcngth of about
40 in. gives, therefore, a ratio of 1: 25. For the force required to opcn
the valves a manual force of 22 to 26 lbs. is permissible - if hand con-
trols are concerned. For se ating of the rocker shaft and for supporting
the valvc housing a cast iron
01' welded pedestal is used. The
hand-Iever with spring-Ioaded
Jatch slides along a graduated
arc and cngages in a numbcr
of registers for the various
control positions.
This manually opcratcd
control gear is placed adjacent
to the operator's stand. It can
bc actuated without particular
effort for presses up to about
1,800 tons. Larger presscs,
however, entail increased fric-
tion- and valve resistances, OI'
the hand-Iever swing becomes
so large that the operator
would get tired soon. There-
forc, even for mcdium-sizc
presses, the indirect dri ve by
means of servomotor is nowa-
days preferred. It consists
Fig. 1:16. Control graf '" per fig. 1:1". primarily of a control piston
which rotates the rockcr shaft
with the speed required and which responds to the movement of the
controllever with minimum delay. 'Vith the servomotor as per fig. l:n,
lever b, which pivots in e, moves out of its neutral position due to a
swing of control lever a, thus transmitting the force through rod b
to the pilot control (valves 1 and 2), hence the control piston e moves
in the desired direction until lever b, which moves along with it, has
brought back the rod d into its neutral position aga in and thus closed
the respective pilot control valve. Consequently, any position of control
lever a corresponds to a certain position of the control piston e and
hence the rocker shaft. The fcatures of the servomotor drive for controL,
are the possibility of employing relieved valves with a high closing
pressure for the relief valve - ensuring good sealing - and easy handling
of the hand-Iever so that the operator will not get tired and maximum
number of strokes per minute may be reached.
CONTROL GEARS 167
If, on the other hand, the rocker shaft is directly driven by hand
without the use of a servomotor, the application of either double-
relieved valves as per fig. 132 or single-relieved valves as per figs. 133
and 134 with relatively low specific closing pressure for the relief valve
- instead of the single-relieved valves as per fig. 130 - is unavoidable
~ Bock/asll
Fig. 1:37. Schematic drawing of servolllotor drive for a valve control.
with regard to the ftow areas in control gears for forging presses . Further-
more, a larger swing of the lever may be entailed.
The controls for the auxiliary devices, such as die slide and ejector,
and the selector controls for staged operation which consist of the same
components as the main controls but usually operate without prefilling
from the air vessel and require - as a rule - smaller valves and corre-
spondingly decreased hand-lever forces, are suitably arranged around
the main control. With regard to accessibility and facility of inspection
of above-ftoor controls and appertaining piping - particularly on large
presses or if several auxiliary devices are employed - the controls are
suitably arranged in a basement and the rocker shafts actuated by
mechanical, electrical, pneumatic al , of hydraulical remote drive. With
this arrangement, the individual control gears may be favorably placed
with regard to the cylinders to be controlled, and piping may be ar-
ranged as to facilitate accessibility and inspection.
The simple mechanical remote control by means of lever and linkage
permits only a limited distance from control gears to the operator's
stand, stiU incorporating the relatively large hand-levers which are
usually handled by the operator in standing position. On up-to-date
forging presses, therefore, a remote control system is preferred which can
be operated from the control pulpit with a minimum of efforts and which
actuates the rocker shaft by means of servomotor.
Remote control systems with these features also take into account
168 CONTROLS FOR FORGING PHF:SSES
the desired increase of number of strokes per minute for forging op-
erations with many constant consecutive strokes, particularly for planish-
ing. The electrical and hydraulical remote controls devcloped in thc
eourse of time work with ample accuracy and the required exact timing
and permit 90 to 140 strokes per minute when planishing with strokes
:l 4 to 3/ S in. long. The expression "timing" indicates thc time within
"'hich the selected switching position has been reached.

As high-speed forging is only economical if close-tolerance operations
are performed at the same time, the operator is freed from prompt
reversing of the controls which requires great skill and utmost concen-
tration, and the controls are provided with automatic stroke limitation,
and precisely adjustable strokes. These automatic high-speed forging
eontrols use the moving crosshead or a linkagc attachcd to it for actua-
tion - as a function of stroke, and with the help of mechanical, electrical,
OI' hydraulical switching components - of the controls proper.
The design of a proven forging control - adapted for open-die

forging as well as for automatic high-speed forging - is schcmaticaIly
drawn in fig. 138. Upon rotation of the inductivc sclsyn e (which is
coupled to controllever a and located in the switch panel b) by manual
actuation of the control lever a, an alternating potential difference
occurs between the selsyn and the check-back position indicator d and
which (being rectified in e and amplified in f) moves the control piston
of the four-way valve IJ out of its locking position and regulates thc
ftow of pilot oiI to the servo piston proportional to the potcntial differ-
ence. Thus the servo piston h is moved - actuating the mechanical
controls StM (see p. 166) - until the turning position of the check-back
position indicator d, which is coupled to the servo piston, corresponds
to the turning position of selsyn e, so that no further potential difference
exists any more and the piston of valve IJ takes its locking position
again. Hence the swing of the control lever corresponds to a certain
position of the piston hand a certain position of the rocker shaft i, the
movement of the rocker shaft i following the movement of control
lever a without any noticeable delay. The pilot oiI of 600 psi. pressure
i8 withdrawn from an aecumulator Sp which is charged by a gear pump
ZP and which switches the feed pump to by-pass if the highcst fluid
level is reached. The bottom dead center of the working stroke is deter-
mined by the elevation of limit switch l - with regard to cam m arranged
on rod n and moving along with the moving crosshead - ~which is
adjustable by remote drive. When it is hit by the cam, the limit switch l
puts the main control automatically to "stop", independently of the
"full pressure" position of controllever a. Not before thc prcss return
has been initiated by the controllever, can full pressurc bc applied for
the next working stroke.
CONTROL GEARS 169
The zero mark of the graduated rule k indicates the elevation of the
bottom tool surface and can be reset in case of wear or after change of
the bottom tool.
For high-speed forging at constant return pressure with strokes of
usually 5/ 8 to 13/ 4 in. , the rotating motion of rocker shaft i , for alternate
-~~-l I
I
I
I
I
I
I
I
~Fig. 138. Automatic high-speeLl forging control as a function of stroke. (By: HyLlraulik, DuisllUrg.)
a Control lever; b Switch cabinet; c Inductive selsyn; d Inductive chcck-back position indicator;
e Rectifter stagc; f Control p anel with amplifter ; O }"our-way valve ; h Servo piston; i Rocker shaft;
1.; Gra Lluated rule; 1 Actual-size switch with adjusting drive; m Cam ; n Switch rod; o I,ever for manual
control; p R eversing unit ; q High-opeed f orging d"vice; r Cam; 8 Adjusting drive.
opening of the press cylinder inIet and outlet valves (see p_ 178), is also
a function of the potential difference which, in this case, may be tapped
off between the check-back position indicator d and the reversing unit p ,
and is caused by the switching operations in the high-speed forging
control q. At any time, however, high-speed forging operation may be
interrupted by controllevcr a and selsyn c.
170 CONTROLS FOR FORGING l'RESSES
In the high-speed forging control q the cam r - being driven by rod Il

through gear and coupling - is rotated according to the crosshead
movement and actuates the Iim it switches 1 to 4; the Iim it switch 1
effecting the return stroke and the remote-sclected limit switches 2,
3, or 4 effecting the working stroke. After switching on the high-speed
forging control, the automatic movement of the crosshead always
commences with a re turn stroke.
For adjusting the elevation of the reciprocating strokes during forg-
ing operation, the whole contact disk of the high-speed forging control
can be adjusted from the pulpit with the help of drive s.
As the points of reversal of the crosshead movement are controlled as
a function of travel of the crosshead itself, it is also possible to produce
accurately sized forgings even with greatly varying forging resistance:
e.g. due to cooling of the ingot. In view of the extremely short switching
and setting intervals of the high-speed forging control, the attainable
number of press strokes is no longer limited by the controlb, but by the
moving masses of the press and the pressure fluid.
By means of the high-speed forging control deseribed, boring rods
of carbon steel, being 30 ft. long and 7 in. in diameter, ·were planished in
eurrent production in 25 minutes on the ave rage ; the diameter devia-
tions over the whole length were only 1/16 to 3/32 in. maximum.
With the automatic high-speed forging control as per fig. 139, the
movement of the moving crosshead is also transmitted - through rack
and pinion - to a high-speed forging selsyn c which operates in con-
junction with the rated value selsyn d in the switch pane!. 1'he potential
differenee - as compared to sel8yn d - ·which is caused by rotation of
selsyn c, is amplified and transmitted to a reversing relay. Dpon change
of phase direction of the potential difference the solenoids of the electro-
hydraulic stroke drive h for the inlet- and outIet valves of the high-
speed forging control are reversed. Hence the moving crosshead reci-
procates about a theoretical zero line where the length of stroke can be
varied in steps - by shifting the upper dead center - by adding thc
corresponding inverse potential to the potential difference in the selsyn
system. 1'hus also the number of strokes changes which, moreover, can
also be decreased by holding - controlled by a time delay relay - the
moving crosshead in the upper dead center. Ey turning the rated valup
selsyn d with the help of a motor M, a fine adjustment of the elevatioll
of the theoretical zero line is possible, while the eoarse adjustment of the
elevation is effected by the main controls.
For eontrolling steam- and air-hydraulie forging presses, valves are
used which are designed in aeeordance with steam engine specification:,;.
Instead of poppet valves also slide valves are employed for steam con-
trols. Slide valves are cheaper than poppet valves but are generally only
CONTROL GEARS 171
adapted for controlling the steam outlet, as they are not suited to shut
off the live steam tightly.
Poppet valves, valve bodies, slide valves, and slide valve bushings
are made of alloyed cast iron. The steam valves (figs. 140 and 141) are
either double-seated with partial relief or provided with single seat which
is relieved by a built-in pilot control valve that may also be separately
arranged in the housing. The single-seated valves are preferred for thc
steam inlet, as they are particularly suited to prevent leakage.
[ofls/rml relum PreJJure waler
r--r~A~~~u~&J(~M~e==========~~~~~~~====fI===C.=V=R;3t=====~
PI ~11_re_~Ji_'lI~_~_wa.fe,_r:·~ fO ... ... RO fi PO i-J
PO'" c:!:."'" ... ... ...
I-{]I------II ... Iligli-speerl ~ Haifl cOfllro/ gear
forg/flg
confrol !lelIr
Fig. 139. Automatic ltigh-speed forging control as a function of stroke. (By: Schloemann, Diisseluorf.)
1'1, 1'0 l'ress inlet- and outlct valvcs; RI, RO Return inlet- and outlet valves; CV Clteck valve;
1<'1, FO ]'illing val ve inlct- and oulct valves for ram.
a Switch pancl (1 Hand lever; 2 Automatic operation in-out; 3 Standstill and operation; 4 Strokl'
eicvatioll adjustment; 5 Sclection of number of strokes; 6 Fine adjustmcnt up-down; 7 Coursc au-
jURtmellt np-uown); b Control panel; c High-spced forging selsyn; d Rated value selsyn; e Phnsc
detector; f lteversing relay; (J 'fime delay relay; h Elcctro-hydraulie stroke tirivc; i Electro·hydrauli<'
tnrning drive; k on pumJ) unit for turning- a.na stroke drivc.
Inlet and outlet valves are either arranged side by side or super-
jacent. Valves arranged side by side (fig. 142) are easily accessible; super-
jacent valves, on the other hand, entail smaller dead space and ensure
proper discharge of condenser water. Depending on the size of free-
space sectional area the valve strokes are 3/Sto 2 in.
The valve spindles and slide valve rods are provided with labyrinth-
or stuffing-box packing and actuated by lever or cam. The force for
actuating the lever should be as small as possible and not exceed 18
to 22 lbs. The resistances of the rocker shafts consists of the existing
partial valve loading when opening the valve, the spring load, their
weights which must be overcome, and the friction caused by slide valves,
stuffing boxes, and linkage, which is taken into account by a cuefficicnt

of efficiency of 0.8.
For calculation of thc flow areas for poppet and slidc valvcs a prcss
wlocity of Vi' = 4 in. /sec. and a return velucity of Vn = 16 to 20 in. jscc.
Jo'ig. 140. ltelieved uOllhle-seatcrl stealll val ve.
:Fig. 141. Single-scated stcam yulvc with bllilt-in relief ,·alvc.
are assumed. The permis si bIe steam velocity for inlet valvcs is Ve = 260 tu
400 ft. jsec., the higher values applying for large cylinder dimensions and
superheated steam_ The outlet valves are usually provided with twice the
flow are a of the appertaining inlet valves. The velocity in the piping
CONTROL GEARS 173
is chosen v = 165 to 200 ft./sec. for live steam and v = lOO to 130 ft. /sec.
for waste steam.
For oil-operated forging presses, poppet valves as well as piston
slide valves are used. The largely relieved pistons of which can control one
slellm
~Fig. U2. Steam val,·c control with "ide·hy·side arranged uouhlc·scated yalvrs allu drivc by sen~o·
motoL (ily: Schlocmann, Diisseldorf.)
or several motions simultaneously. Fig. 143 illustrates the design of an

oil-operated three-way control valve for two positions, with hydraulic
pilot control. It may be used, e.g., for controlling the press return by
charging the return cylinders with high-pressure fluid from an accumu-
lator for the advancing motions , and by connecting it to the prefill tank
Pre.ssure in/el
:Fig. H~. llyrlra\llieally pilot-tontrolle,l

thrrc-wa v valve for two po~ ition :-,.
(lly: Sehwietzke, Dii:<scJdol'f.)
CirCI/ii rlio;rorn
for the return motion; the required discharge pressurc in the return
cylinders being generated by the main ram which is under filling pressure.
The ground twin-piston a, which is provided with sealing grooves,
is balanced with regard to the accumulator pressure and is constantly
pressed against the push-rod c of the control piston d, since chamber b
is connected to the air vessel and chamber e to a pressureless reservoir.
In the position shown , the working cylinder is connected to the aiI"
vessel. When the pilot oiI enters the chamber f via the pilot control whieh
is not shown, piston a is shifted to its left end position, closing the port
CONTROLS FOR ACCUMULATOR-OPERATED FORGING PRESSES 175
which connects the working cylinder to the air vessel and opening the
port from the accumulator. The schemat.ic drawing of the valve shows
the flow of oiI through the three ports in the two valve positions.
The accurately sized clearance of the pistons permits leakage of small
amounts of oiI towards the piston sides of lower pressure; it serves for
Iubricating the sliding surfaces of the pistons and is discharged into the
air vessel on one side and into the pressureless reservoir on the other side.
b) Controls for AccuIDulator-Operated Forging Presses

Fig. 144 shows the hydraulic circuit of a three-cylinder forging press
with accumulator operation. By arranging a prefill valve at each cylinder
and by employing a selector control with the valves 1 and 2 it is possible
- after carrying out the idle stroke - to feed the pressure water either
into the middle cylinder only or into the two outside cylinders only or
into alI cylinders. During the working stroke the water flows from the air
vessel through the prefiIl valves into the non-operating cylinders. Hence
it is posRible to forge with three different pressure stages and to sa ve
large amounts of pressure water if forgings are produced which do not
require the fuII press tonnage.
The design and function of the main control is known from the de-
scription for fig. 122. The setting for the three pressure stages may be
noted from the Iever positions V, VI, and VII, and from the valve lift
diagram for the selector control.
The selector controlmay also be combined with the main control and
actuated by only one hand-Iever, the control positions "fuIl load" 1,
2, and 3 being indicated on the graduated arc. This arrangement has the
advantage that the operator is forced to always commence each stroke
with the lowest pressure stage. The drawback, however, is the non-
positive connection of the rocker shaft with the lift rods for the valves,
which causes such large controllever and valve stroke movement that
more elaborate cam drivc has to be employed.
Fig. 145 illustrates a hydraulic circuit diagram for a forging presR
which has been converted from steam-hydraulic to accumulator op-
eration (see also fig. 106). Such conversions are ma de to in crease the
economy of the forging press and in order to be independent of a boiIer
plant. In most cases, the conversion entails only modifications to the
puIIbacks and the filling valve. Instead of a steam intensifier generating
water pressure of 5,700 to 7,000 psi. a hydraulic pressure intensifier is
employed, the low pressure end of which is charged by an accumulator of
usually 3,000 psi. With this arrangement, two pressure stages with a
ratio of approx. 1:2 are available for press operation. This solution,
however, is not recommended for new designs, as the arrangement of
three press cylinders is simpler and cheaper.
176 CONTROLS FOR FORGING PHESSES
The main control consists of the controlled valves 1 to (j and check

valve R. The valve strokes in the control lever positions "full load" 1
and 2, "advance", "stop", and "return" may be noted from the valve
//iT/ve MI tlillgl'tlm
L:tJ
J!lI l i Y
..,
:!:l,
{
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Fig. 144. Hydmulic circuit dia gram for aceumulator·operated three-cylindcr prriiii with power "tngc
control gear.
lift diagram. In order to avoid exceeding of the common control le vre

swing of 24 to 28 in., the pressure intensifier control is provided with
hydraulic drive of the lever shaft.
The mode of operation of the press in the "advallce" positioll is
already kIlOWIl. "\Vhen forging with "full load" 1 thc prcssure water is
CONTROLS FOR ACCUMULATOR-OPERATED FORGING PRESSES 177
fed from the accumulator through valve 3 into the press cylinder. In
position "fullload" 2 the pressure water fiows through the opened valve 5
into the cylinder chamber b, thus overcoming the constant pressure in
i,~
Ir
e
VrJlve lift di(]/lrom

II l/l .lY
Fig. 145. Hydraulic circuit diagram for a RteulII-hydraulic forging prC8S for two prcsRurc stage8 whieh
has been converted for accumulator operation.
chamber a and opening valve 5a for the pressure intensifier. The pressure
water enters the low-pressure cylinder c and lifts the plunger d which also
serves as a high-pressure cylinder and which forces the intensified
pressure water through plunger e mounted to the upper crossbeam into
the working cylinder of the forging press. Check valve R prevents the
fiow of the intensified pressure water into the accumulator line.
The amount of pressure water to be delivered by the intensifier is
sized to single strokes commonly adapted for steam-hydraulic operation
(see table 12, p. 101). Progressing single strokes with "fuIl load" 2 are
carried out by shifting the control lever repeatedly into position "fuIl
12 l\'liillcr, H~'llraulic Forging Presses
178 CONTROLS FOR FORGI:'>'G PRESSES
load" 2 aud back iuto positiou "stop". Iu position "stop" (valve (j

open) the rcturn motion of the intensifier plunger d commences due to
thc return plunger f being under constant accumulator pressure.
c) Controls for Steam- and Air-Hydraulic

Forging Presses
The hydraulic circuit diagram for a steam-hydraulic forging preHR
with stcam return cylinders is shown in fig. 146. Thc steam is controlled
only. The water is used for prefilling the cylindcr and as transmission
medium between intensifier ram and press ram. The valve positiom:
shown on the valve lift diagram correspond to the control position"
"full load", "advance", "stop", and "return" on the graduated arc of
the control lever.
During normal forging operations the selector lcvcr a is connected
to the controllever b by means of a rod c. In the illustrated controllever
position "stop" all valves are closed except the re turn inlet valvc 1 and
the bore of valve pistou 6 for thc outlet from the drive cylinder of the
prefill valve. Dcspite the opened inlet valve 1 for the return cylinder
the return motion cannot take place as the drive cylinder for the filling
valve is connected to thc \Vaste steam line, thus keeping the filling
valvc closcd.
Hence the return rams push against the closed cylinder whilc with
accumulator operation (see fig. 122) in "stop" position, the press ram,
being under filliug pressure, rests against thc closed return cylinders.
In position "advance" valve 1 closes, while the return outlet valve 2
is being opened. Due to its own weight and the pressure of the filling
water, which lifts the filling valve and flows into the press cylinder,
the press ram with the crosshead lowers until the upper ilie hits the
workpiece.
If the controllever is shifted into position "fullload", valve 3 opens
for the steam intensifier, and the forging stroke is carricd out by the
up-motion of the intensifier ram.
Upon shifting into position "return", first the valves 3 and 2 arc
closed and then valve 1 and the outlet valve 4 of the steam intensifier
are opened. By diseharging the steam through valve 4 the intensifier
ram moves down and relieves the press cylinder. Finally the prefill valve
is pushed open by closing of slide valve bore 6 and opening of bore 5.
The press ram moves up and displaces the water of the press cylinder
partially into the aiI' vessel and partially iuto the pressure cylinder of the
steam intensifier, the latter taking its lowest position again.
The motion of the drive rod for the prefill valve is controlled by a
special piston with thc bores 5 and 6, in order to ensure maximum num-
CONTROLS l?OR STEAM- AND AIR-HYDRAULIC FORGING PRESSES 179
bers of stroke when planishing, and to carry out progressing single strokes
for piercing or upsetting operations.
The number of planishing strokes - up to 80 ar 100 per minute for
small and medium size forging presses and about 50 to 80 per minute
Va/ve /ir; a'iagram

I Jr 1lI ../Y
~M I forging
II Advance
IT Plonishing
8
J![ ProgreS'S'ive S'ingle slroke.r

JI[Stop
JY Refurn
Con/rol/ever- Chonge-aver lever-
Patiliont
Fig. 140. Hydraulic circuit diagrarn fol' a stCUJIl- OI' air-hydraulic one-cylindcr forging pres:;.
for Iarge presses, and a penetration depth of about 3/4 to F/4 in. - are
attained if the return rams are subjected to constant pressure and if the
filling valve is continuously kept closed. Thus a standstill position is
achieved in the "advance" position. If the control lever approaches
the position "fullIoad" and "return" , valves 3 and 4 are actuated only,
in this case the water column oscillates between press- and intensifier
cyIinders; the drawback is the Iarge amount of steam consumption, as
12*
180 CONTROLS FOR FORGING l'RESSES
the idle stroke of the press plungcr as wcIl as the working strokc arc
carried out with full pressure.
According to the valve lift diagram in position "stop", that is whell
valve 1 and valve piston bore 6 are opened, the specified condit.ions for
planishing are met. If thus - in standstill position - the ReJcctor lcver
a is locked and disconnectcd from lever b by removal of rod c, then control
lever b only actuates the steam inlet and outlct valves 3 anei 4 according
to the above-described mode.
There are different solutions for the control gear drive dc:;lÎgn. By
employing a hoIlow shaft, for instance, both axles could bc combined
and lever a be locked by a pin.
Progressing single strokes are the addition of several consecutive
working strokes of the press ram without intermediate return. Such single
strokes are carried out if the return cylinders and the drive rod of thc
filling valve remain connected to the waste steam line, that is if selector
le veI' a is locked in position "advance" and if valves 3 and 4 arc actuated
by controllever b.
The automatic reversal of the controls to return, at end of stroke
of the steam piston, by the shutoff linkage on the intcnsifier must be
performed without any movement of the controllever as to not endanger
the operator. For this purpose - as per fig. 146 - the rod d cngages a
lever a which pivots in f if control levcr b movcs. If the piston of the
steam intensifier is raised, roller IJ moves along the rule h. The rod 1:
moves up, thus turning the lever e around pivot k; hence the inlct
valve 3 is closed again and outlet valve 4 is opened in the upper end
position of the steam piston without moving the control Jevcr. 1'he stroke
of the steam piston always corresponds to a eertain swing of the eontrol
lcver - even if taking into account the expansion of steam in the inten-
sifier in case of low forging resistance - by the help of which, therefore,
the penetration depth during forging can be regulated.
A safety shutoff pin is located so that the sten,m piston will strike
this pin (as shown in fig. 86, p. 102) and shut offthe steam bcfore damag-
ing the upper end of the cyJinder. If the dimensional requirementR arc
not too great, the skill that an operator wiU deveJop is suffieient to keep
from damaging the press and the movement of the shutoff Jinkagc is a
safety measure which is only seldom necessary. Thi8 design is frequcntly
used due to its simplicity.
The shutoff linkage may bc eliminated if a eushioning spaee is pro-
vided in the upper cyJinder flange. If, in this case, the steam piston has
eovered the outlet ports at the upper end, a return passagc from the
lower to the upper end is connected through which li ve steam stream:,;
via check valve into the upper eylindcr chambcr and is subscqucntly
compressed and thus absorbs the kinetie energy of the piston.
CONTROLS FOR STEAM- AND AIR-HYDRAULIC FORGING PRESSBS 181
In the hydraulic circuit diagram as per fig. 146 the lower ends of the
return pistons are controlled. However, it is also possible to control the
upper ends of the pistons by applying constant steam pressure to the
bottom sides of the return cylinders. This keeps the return cylinders
uniformly warm. The control diagram changes only by exchanging the
return valves. When making a decision as to which piston end is ta be
controlled it must be considered that the steam consumption in the
return cylinders depends on the elevated position in which forging
j<·ig. 147. Control in thc cylindrr bottom of a steam intensifter with rc\icved singlc-seated
inlet valve and double-seated outlet valve.
(lly: Banning, Hamnl.)
operations are mostly carried out. For this reason, e.g., controlled bottom
ram sides will be preferred if forging operations are chiefly performed in
the lower half of the stroke range, since in this case steam consumption
is lower as compared with controlled top ram sides.
In order to keep the dead space in the steam cylinders as small aR
possible, the appertaining valves are directly arranged at the steam
cylinder of the intensifier or in the cylinder bottom (fig. 147) and at the
return cylinders, assuming, however, that in the latter case the distance
from the operatol"s pulpit is not too large.
If a steam-hydraulic forging press is provided with hydraulic return
devices, the return control is separated from the steam control and
directly placed adjacent to the operator's stand, as no more consid-
eration has to be given to the amount of clearance volume. In view of
simplicity the filling device is also designed for hydraulical operation.
The hydraulic circuit diagram does not change.
182 CONTROLS FOR FORGING rRESSES
d) Controls for Forging Presses with Direct Pump Drive

In order to attain a uniform movement of the press ram, one 01'
several eoupled triplex pumps are employed, for oil operation also
multiplex pumps with constant or varia bIe delivery are used. Th8
hydraulic circuit diagram for a direct-driven forging press is shown in
fig. 148. The valve locations in the various controllever positions may be
Valnl lift diagro m
GliA
4 J 2
~
_ 17"'::.........o::......- =--tJ
:Fig. 14R. Hydraulie cirenit diagran1 for a. forging prcss with direet plunp uriYc.
noted from the valve lift diagram. In the shown position "stop", valv('s
3 and 4 are opened with the pumps running idle. Down moving of thc
press ram is obviated by the closed control valve 2, thus preventing
the pressure fluid from discharging out of the return cylinders. In posi-
tion "advance" valves 3, 4, and 2 are open, the pump continues to run
idle, the press ram moves down due to its own weight and the filling
pressure which opens the filling valve. The return cylinders are dis-
charged through valve 2. In position "fullload" valve 4 is closed. Now the
pump delivers into the press cylinder and a pressure corresponding to thc
CONTROLS FOR FORGING PRESSES WITII :VIECHANICAL INTENSIFIER 183
forging resistance will develop. If the pressure exceeds its maximum

value, piston 5 overcomes the spring load and opens by-pass valve 7,
unloading the pump. Check valve 6 prevents the main cylinder from
being discharged. During the press motion the cylinder pressure is
effectived by the return rams, which has to be taken into account for
sizing the main ram diameter. At "return" position valve 4 is opened,
the press cylinder relieved and the by-pass valve closed by the retraction
of piston 5 while the pump is unloaded due to the opened valves 3
and 4. It delivers against pressure again after valve 3 is closed. In this
position valve 4 is opened so that the return motion can take place,
since valve 2 is forced open by the fluid pressure. The fluid discharged
from the press cylinder returns into the air vessel through the prefill
valve which has been opened by the push-rod.
When designing a hydraulic circuit diagram for direct pump drive
of the press, care must be taken that in no control lever position all
valves are closed as this would cause a shock in the pump line and a
sudden opening of the by-pass valve. The lines in the valve lift diagram
must, therefore, overlap. For accumulator operation, on the other hand,
appertaining inlet and outlet valves must under no circumstances be
open simultaneously, as then the accumulator would be connected to
the reservoir directly.
e) Controls for Forging Presses with Mechanical Intensifier

Fig. 149 shows a hydraulic circuit diagram for a forging press with
crank gear intensifier. If the intensifier is activated by shifting the clutch
lever, the press performs reciprocating motions automatically. The water
column oscillates between intensifier cylinder and press cylinder.
By means of the clutch single strokes may also be carried out, the
penetration depth being regulated by precise actuation of the clutch
or by opening the water outlet valve 2.
If the elevation of the reciprocating strokes is to be lowered, water
is fed from the low-pressure vessel through valve 1 into the press cylin-
der; on the other hand, if the elevation of the reciprocating strokes is to
be raised, the water is discharged from the press cylinder through
valve 2 into the reservoir.
On performing the same control operations when the clutch is dis-
engaged, the press ram idles up and down. The constant return load is
overcome at down-motion by the larger force of the press ram.
Hence the feed of low-pressure water for lowering the reciprocating
strokes during the automatic operation cannot take place when the
upper die penetrates the workpiece, as the pressure in the press cylinder
is greater than the pressure in the low-pressure accumulator. On the
other hand, check valve R prevents the pressure water from flowing
into the low-pressure line.
The low-pressure water withdrawn from the accumulator is replaced
again by an auxiliary pump. Starting and stopping of the pump is done
automatically: - upon a certain pressure in the accumulator the suction
valve of the pump is lifted by the plunger and closed again if the pressure
drops. An accumulator control is not necessary as the water level is
III
lf r
\ /
lTig. 149. Hydraulic circuit din gram for a forging preRs ,vith eTank graf intensifier.
indicated by a level gauge and as aiI' losses may be compensated for by

starting and stopping of the pump.
The drive of the auxiliary pump works independently of the cluteh
for the intensifier. Frequently a separate drive motor is provided for the
auxiliary pump.
The hydraulic circuit diagram for a two-cylinder forging press with
spindle intensifier is illustrated in fig. 150. In control lever position
"forging" control valve 1 is open. Valves 2 and3 are closed. Both retu I'n
cylinders are connected to the accumulator through the open val ve 6
and are undeI' constant pressure. Both press rams move up and down
according to the reciprocating motion of the intensifier ram, the drive
motor of which is controlled in conjunction with an Ilgner-sy"tem, aR per
the electric circuit diagram described on p. 113. Within thc limits of the
intensifier stroke, press strokes of any size can be carrieei out, constant
CONTROLS FOR FORGING PRESSES WITH lHECHANICAL INTEN SIFI ER 185
reciprocating strokes may
be a t a. ined automatically
by respective etting of
the electrical control .For
<::hiftinlY the elevation of
the reciprocating . trok s-
for adapting to the work-
ing height 01' if the hot
stock is to be turned over
- the volume of the o cil- 01/.'5.10:1 ~-~~"*"'
la,ting wa,ter column is dOIS-
decrea ed ur increa ed by
means of the control po i-
tion "return " OI' " Iower-
ing". In tbe "l'eturn"
position va.lve 1 and 3
are opened while valve 2 remains
closed. The moving crosshead rai e ,
the wa el' in the pre cylinder being
discharged through vahre 3 into the
aiI' vessel which is arra,flged adjacent
to the control. n " -tandstill" po-
sition all valve are closed and thc
intensifler is shut down. The water in
the two l'eturn cylinders di charge
through the open valve 2. The
moving cro "head i lowered , filling
water flo\\"ing now from the ail' ve el
through ch e kvalve 7 into the main
c,) linders. The water in thc ret llrl1
cylinder i di charged through va lve
2 into the uction ves 1 of the pre:'-
Sllre ",ater pump and i de li vered
through valve 5 into th a cumu-
lator. If th accumuJator is chal'lY d ,
a olenoid lifts by-pa valve 4 and
the pump deIiv l' into by-pass.
Check valve 5 pr vents a backflo\\'
of pressut'{' ,,"atcr fl'om t.h a cumu-
Iator. The hio-b- peed shutoff va lvc
6 i constaJltly kept open by il sole-
noid and e10 ed only if the accll-
mulator is empty , in order to prevent
186 CONTROLS 1"OR FORGING PRESSES
the compressed air from ingressing the hydraulic circuit. Ovcrloading

the intensifier is obviated by a safety valve and by rcversing the drive
motor by means of a contact pressure gauge. Moreover, limit switchcs
are provided for the intensifier stroke.
f) Controls for Hydraulic Auxiliary Devices

Fig. 151 shows the hydraulic circuit diagram of the shifting tablc
and the ejecting device for a forging press. The reciprocating motion
of the shifting table requires a gear with four valves; the ejecting device,
on the other hand, requires for the up and down mot ion a two-valve
control only due to the arrangement of restoring weights, which is
<:::; ~ 1ţ:; .1?> ~

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<:
-<:"!
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-<:"! ""~ i:;
-<:"!
~ ,@- ~ <ţ
;:;,~
~
fflJlT/ IJccllmll/lJlor
~ i.5l ~
~
'" drrye
ACCllmll/lJ!or f'IImpdrJYe flJ e/evIJlerlllJnIr
Fig. 151. Hydraulic circuit diagram of the lable shifting and ejccting devices for a forging I,re"s.
generally the case where a weight, a spring load or a constant-pressurc,

return cylinder are provided for retracting the rams. However, replacing
a pair of valves by one of the afore-mentioned measures is not in every
case suitable since costs have to be considered too.
The valve lift diagrams show the setting of the valves for accumu-
lator- and for pump operation. The distinguishing difference is again
that for pump operation the valve lift lines overlap, thus taking up the
delivery in aH controllever positions and the pumps running idle if the
inlet- or outlet valve is opened.
HYDItAULIC CIRCUIT DIAGRAMS 187
The calculation of the free-space sectional area of the valves should

be based on the water velocities given on p. 163, the smalIest valve
diameters, however, are chosen not below 0.600 in.
The shifting and ejecting velocities are v = 4 to 8 in./sec. Ii large
shifting strokes are performed, the speed is increased up to v = 16 to
20 in./sec. and shortly before the end of stroke the pressure water feed
is throttled to avoid an impact at the end of the stroke.
The throttle devices consist usually of a valve which is closed by a
cam on the shifting table. Bya small center bore in the valve the pressure
water feed and thus the final velocity is de crea sed to v = 2 to 4 in.jsec.
g) Hydraulic Circuit Diagrams of Carried-out

F orging Press Installations
Fig. 152 illustrates a complete hydraulic circuit diagram of an
existing steam-hydraulic 2,750-ton three-cylinder press. The press has
steam returns, an air vessel arranged above the main cylinders, a shifting
table, a shifting device for the lateral die change, and an ejecting device.
AII auxiliary devices, including the pusher rods for the three filling
valves and both valves for selecting the pressure stages are activated
hydraulically and connected to a power water station with an operating
water pressure of 5,000 psi.
The main control is provided with the relieved inlet valve 3 of
9 1 / 2 in. diameter and the double-seated outlet valve 4 of 12 in. diameter
for actuating the steam intensifier. The bottom sides of the return rams
are subjected to constant steam pressure. The top sides are controHed by
the relieved valves 1 and 2. The main control shaft is activated by a
servomotor and connected by means of linkage and clutch to the re turn
control shaft which also actuates a hydraulic control with valves 5
and 6 for the push-rods of the filling valves. At normal forging operation
the main and return control shafts are coupled. For planishing and
when performing progressing single strokes, the return control shaft is
disengaged. In the first case valves 2 and 6 are constantly opened and
valves 2 and 5 closed. The return cylinders are under constant pressure;
the filling valves are closed. In the second case valves 1 and 6 are con-
stantly opened and valves 2 and 5 closed. The returns are out of action;
the filling valves are closed and act as check valves. From the valve lift
diagrams the valve positions in the various controllever positions may be
noted, irom which the sequence of press operations can be trailed.
Fig. 153 is the drawing of a hydraulic circuit diagram of an existing
three-stage, accumulator operated, 2,750-ton forging press. By means
of the stage control the pressure water is fed either into the middle
cylinder only or into the two lateral cylinders or into aH three cylinders,
thus establishing one of the three pressure stages: - 916 tons, 1,832 tons,
or 2,750 tons. The small outlet valves 2 and 4 in the stage control gear
are to prevent - when remaining in "full load" position - a gradual
building up of pressure stage 3 if the inlet valve 1 or 3 of thc stagc
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r!I!
Plonimin; t:rJn/rri§WI' Sloge c{)IJ1roI !letll' Nain con/rol geti!'
~
><
t?
ţ:;I
:..-
d
r
O
O
tdO
d
::3
~
:..-
<:;'l
JlI Jl ţ:;I
:..-
o:
[fl
~
~ .~
~
....
]t;;;
Fig. 153. H yut"Uli c circuit dia gram fot "" 3CClII11111alor ......
opcrnted 2,7:,0-tOIl lhrce-cylinctcr f orging ]lrcs.~. 00
(D
190 CONTHOLS FOR FOHGING PHESSES
control is not tight. At pressure Rtage 1 thc selector control is releascd

by means of rod a; in position "planishing" the selector control applieR
constant pressure to the pullbacks and at the samc timc also activat,e8
the pushcr roos of the filling valves for the two out si de cylinckrs, thus
ensuring idle motion of the outside press rams. 1'he filling valve of the
middle cylinder, which is seperately coutrolleel by valvc8 5 and 6 of the
main controls, i8 closed during planishing opcrations, as stop plate li
prevents the main controls from approachiug the position "rcturn".
The main controls, activated by a servomotor, are also provided with a
neutral position - besides the working positions "fuU pres8ure", "ad-
vance", "stop", and "returu" - in which all outlet valves arc opencd,
the upper die restiug undeI' filling pressure against the 10we1' die. In this
position, which i8 used to shut down the press for short periods of time
- for instance for lunch breaks - and which is locked by pin c, neithcr
fun pressure can build up nor can the press ram "crecp" upward, in
case of untightness of an inlet valve.
The pressurc connection for the servomotor is arranged before thc
main shutoff valvc for the controls, so that it can be useeI for adjusting
the control valves when the main shutoff valve is closcei.
Check valve Rin the pressure line prevents - if thc accumulator. i8
empty - withdrawal of water from the press for other units. 1'his prc-
cautionary measure is necessary to prevent - e. g., in case of tool change
when the moving crosshead is raised - the rcturn cylinders from being
discharged through the check valve adjacent to valve 1, cau8ing a
sudden drop of the moving crosshead and endangering the opcrating
personnel.
In the filling line, close to the cylinders, an auxiliary aiI' vessel is
arranged which prevents water hammer in the filling line duc to the
mass inertia of the filling water.
The control of the table shifting and the outside die shifting is eflected
by one four-way valve each. With the help of mcchanical dcviccs the feed
at the end of stroke is throttled, while at thc beginning of motion the
whole orifice is opened due to the check valve effect.
Fig. 154 - according to an English trade journal 1 ) - shows thc
hydraulic circuit diagram of an existing 7,700-ton one-cylindcr forging
press with direct pump drive (see p. 89). 1'hc ram diameter is 60 in.,
the operating pressure about 5,700 psi. AH auxiliary dcvices, that is
shifting cylinders for the tables, two re turn cylinders with 17 in. dia-
meter rams, two balancing cylinders with 7 in. diameter rams and thc
hydraulic drive for the main valves, are connected to a power water
station with approx. 2,250 psi. operating water pressure.
1) J. Iron SteeI Inst. 161 (194B) February.

Seqllence of opera/iolls
-
" . . . " " . t7:on tiffing eylinl/er vo/ve , ,
I ' II!, I ~~, H~'''nll~hc CII'Cllit d,,\~t"l11 ,or It 7,000. 1011 I'urging pres,; pas. fl'f!ssure Emou,1 fotyevolve Pl'f!ftllvOM!
II'I Lh lhrect I'"IIIP """0. (J, lro ll :;Lcel lll st,l 1 Jl"flI/iflg closet! closet! MIraM" cJo.ret!
ii ro!'giflg closet! open closet! dosi!tl
1 J'!u,,(/i/Jff obOl/l1D apei> closet! lIo/fopen "boul'" opel!
J l;lling Of"" cloml fuI! _pen fullof!en
, J/ipplil/ I'!/ve ~ HotI/fi elam clos!!d cI= rem/Jins
Junc/ioll IIlgh -pres.rllf'e for retiuC/ng 1 s!umliflg IJfJI!n
, b/od shu/l-off IIflIPIJ I"eplY!J'.f.spefli f-:--,,;;-;I.::-""---ll---- - + - - - - I -- - --I--- -
.. It' <
,,'uore, pteMute 1'0
, pte.r.r, -','
h) 'b0I'e . •• I'f!
rr r"""._rJ. ro1 .an mlll
ro/fU1' Iir closet! opet1$ c/oses '
1'f!/fIOlfI,J
/ velocily SJJ ftlSEc J~ Z forgif1Q open
I , I t:l
fi4 . 2 rorgil/g closet! open closet! closet! ::t:
><:
tj
~ ~ ~ ~~2 ~
r-- rto oiI' VlJssel 10 ufler d=d closes opem closet! !;lj
;.-
I ,' "bal'{! ~;~s~lu~n~~~~~------~------+_------~----~ c:
h ,1- ' 1----'---- COfl/rol va/V(! for to Re. tii r
~!:;: I b= II:: loweig/ll 1z'bare SlJMJnlO/or (forţjin/) I!.J_ 'fII!
_....L._ _....L._ _....L._ _....L._-----.J
:=i
a
./. ~ ... / __ .~ 6u/oncinn fo~ss n . :n - . i ~ A' I
~ '=:t=' F cyhnder:' LlI'/l~ ~a ~plr ~
a
'1SlI.f5 _ ,mv,:,%r !lenZ;oIlK'~
' t
.....,Ci
}- f- (fil/mg) t ~/um I/I(]in
va/VI! I i !. . .Woler gouge tj
...
:>-
S I ~ ~~ \~ ~~ a
!;lj
;.-
JO[IrJ 1 L ~ ~: ,~~~::1; - I I ~~ I ~~pplf a::
[fl
O• i' • O .f::! l Mtirfpod lor n l--b. 12' bare. suc/ion frompllHlp

• ~ S'bore.§ ( ,---- 1-
~ ~va/VI!
L.j- l;I7;'ng , ...) r - Pump,
~ CYlinn~VbI
W! JiI li I .L ~ ~~pebut:f/J' con.r/on/ speetl
~ ~ 1,...,., ~~J ~ " ., !il i.j IJfIdjllfollliuru rob§tle;. peok lood 0,5(J(J HP
'~ ,§ ~ S'eKllawl ExhOlr.r! ~n/l'Il/ voll1! Whirlpool ~~ friple lokly wfit: ~ ~ opera/ing pres.ure uppro)" /iDOOp:
~ i' :.::s ~ Emf!I'9Co cr ~ fiJr «:; ~ .se/Io b/ow r-' ma.rpre.rsllre oppro.... 6;.?OOpŞI
Z i+_.,3 o hpnd/ever F!:lB OUKllliory '12'<" " ", ~ 'S offol43lJOpSi crank spud 9Srpm
\:;::t-- -\ . va/ve wf'e, /III/flf li " / '~
..1-- _.., 'Îil!.' ,1 ofldrelumptpe ~ il G'a- _ _~r
'~ - - '~\\ .....
~
\.-1-110111 ~ 1,1 10// l~ nou(1 ";1J J1ll "'(~ , .....
hond/eveJ' IRelurn ' IAMtm . ~ .-'
,OpeM/or '1:,., ==
.--Şloe · ,f'btJre
- - . -
'ry dl'l/lC.
pl'f1ssure 6,ZifO psi
The following speeds are indicated: pressing about 2 in./scc., lower-

ing about 6 in./sec. and retum about 8 1 / 2 in./sec. The control lever hm;
three working positions: pressing, neutral, and return. The main control
shaft activates three two-way valves - connected to the accumulator
line - which belong to the retum cylinders (lifting cylinders) and to the
drive cylinders for the filling- and pump by-pass valves (main prcss
valve). The by-pass valve has a diameter of 9 in. and a relief valve of
1 1/ 2 in. A relieved valye with large flow are a may suitably be used, in
order to achieve large numbers of stroke and to attain a quick discharge
of pressure from the main cylinder upon reyersal of the controls. Thc
yalve motion follows - by means of the activating linkage for the two-
way valve control - exactly the motion of the hand lever. As the yalve
is closed in the pressing position, a filling valve is provided - for filling
the main cylinder when lowering - having a diameter of 12 in. and a
relief valve of 11 / 2 in. diameter. In order to maintain the flow arca also
for retraction, the valve is opened by a hydraulically activated lever
shaft. This drivc also permits manual control of the valvc with the help
of a special hand lever in case of malfunction of the controls. The shutoff
and throttle valves - arranged in a branch line - regulate the press
speed and maintain the pressure. The filling and return water is in an aiI'
vessel undeI' 70 to 140 psi. pressure. For avoiding water hammer when
the filling valve and the forging valve are open, shock absorbers are pro-
vided behind the valves. To protect the drive motor of the pump, the
electric current is automatically switchcd ofl:" at a certain drop of rota-
tion, which is also indicated by a red lamp.
h) Indicating of Forging Presses

The readings at forging presses and power water stations are per-
formed by the recording of diagrams. There are pressure-way, time-way,
and pressure-time diagrams which are recorded by indicating instru-
ments, by diagnostics, and by manographs.
The indicators are of same design as used on piston engines and arc
on hydraulic cylinders connected to the vent- 01' drain bores.
The diagnostics serve for determining the various ram velocities
and are to permit also large-scale indication of partial strokes, c. g. the
working stroke (fig. 156).
Manographs are used for easy reading of the various numbers of
stroke and are provided with a variable paper feed. With thcir hel}J in
many works the total forging operations are recorded (fig. 157) to enable
the forge master to subsequently check the sequence of operations
carefully. The manographs can be arranged such that they represent no
obstacle while the indicators and diagnostics have to be arranged
directly at the press and are, therefore, relatively seldom used.
INDICATING OF FORGING PRESSES 193
6CJ~.....
" '",
~-
c = = J0leSllrlOee
j;'ig. 155. ltise of steam pressure in the intensifler for a 1,300-ton forging press (as per DAELEN:
Stahl u. Eisen 1898, No. 18).
Table 22. Specijications jar Diagrams as per fig. 155
Din- Pre 'urc arca. ln!lol, Line

gmll1 cross sec.tioll stcam prCSSUfC
Xo. in. in. psi.
1 10'/4x 12 '/2 101/., x lO l/., 60 very hot

ye llow
2 101/~ x I2' /2 101/4x lOl /. 60 slightly coldcr
d" rk yello"-
3 10' !~ x ] 2' /2 101/~ X 10' /~ 60 further coolcd
red
4 4 3/ s x 12 1/ 2 12 X 43/~ 63 dark red
5 4 3/ 8 X 12 1/ 2 12 X 43/~ 63 further cooled
brown
6 4 3/ s x 12 1/2 12 X 4 3/ 8 61 further cooled
a lmost black
7 10' /4x 12'/2 JO'/'\x lO ' / t 61 moderate ly hot
8 31 x l '2 I / 2 60 redwarm
Fig. 158 illustrates indicator diagrams of a steam-hydraulic 1,300-ton

forging press; it can be noted from them that the intensifier operates
with prefilling and that the steam is throttled according to the forging
resistances.
The pressure rise at the beginning of the intensifier stroke is thc
result of the steam entering the lower cushioning space from which it is
fed - not before a short stroke of the ram has been performed - at a
large drop of pressure into the steam cylinder. Throttling of the waste
13 :r.Iiiller, Hydraulic Forging Prcsses
Ploni.J/Jing
~~[Ar\E"'"'1~r-~"'"'-
i ~ V'fvvVţO.lrokes/min
1.0:
1
?Jdro~/spmin~~5slroke4mi~ ~
IJ,S f.rlrokc.r/Mmin=
I I I I
~
I !
~.v4"fmin~
I I
J5drolre.r/*Jmin 8,Ssfroke.s/min
I I , t r I I
tJ.rIll1k:jfmm
I , I
Q 1 Il J ~ 5 o 7 8 9 10 11 16 fl 1? 15 10 17 18
Toiul ,ylrok~ (], min
~:f0~1
~zoo -
~
;;?VW n -
100 ~~
I I I I I I I
O !ţ1 !ţI! !ţJ o.~ C/5min 46'
Por/ia/ s/roke b
Fig. 151). niagllo~tie~ rernrding of tiulc-way diagr<lms in slilalI nud pnl:uged ~('ak 011
a 2,20U-ton fOJ'gill.~ ]JJ'{,~S (a~ lHT KALKHO}'; Sbhl 11. -Eisen lH:~J, Xo. :1;.!).
tJ b;1/
---
- .125 - - '190 - -
/1~)
. - 075- -":
Fig. 1:')8. Il\(licator ,liagnlllls of tllP stl'<llll- all<l of the pn'ssun' wafe}" evlilHlt'r of tlw
intcnsificr for a ],:300-toll fnTgillg prC-'ss (as pcr K .U,KHOF: Stahl 11. Hhcn 1n:JL Xo. ;):.!).
Oie Chonge
Q
mm
Fig. 1;')9. Indieator diagranls of thc steanl cylinrler uf thc intensitit'f anu simnlt.:.IIlP-
uusly recordrd time-way and time-pressure diagrallls by diagnostks 011 a ~,~U()-t()n
forgillg prr~s (as !lCl' KAJJKHOF: Stahlll. J<:bell lU:H, Xo. :J~).
Fig. 157. COl1r~e of forgillg operation durillg prodl1cJioll of a gUII harrel. Hule })itdl
Fi!!. ]57 1/2minute.
EXAMPLES OF DESIGN AND CALCULAT ION 195
steam upon reversal of the intensifier motion is caused by the relief of the
press cylinder, only after which the filling valve is opened. By comparison
of the generated and the utilized work from the steam pressure and
ram pressure diagrams of the press, the efficiency of the steam inten-
sifier (and by means of lead pressure tests, the total efficiency of the
press unit) may easily be determilled. The losses are caused by friction
in the stuffing boxes, flow resistances, Ieaky points, and the compressabil-
ity of the pressure fluid.
Fig. 159 shows the compilation of simultaneously recorded indi-
cator- and manograph diagrams of an intensifier and the diagnostics
diagram of the forging press which indicates the performance of two
subsequent single strokes by the lines 1 and 1 a. The diagrams show ,1
distinct conformity, permit the determination of the peak efficiency of
the press and give information about the velocities during the advance,
forge, and return strokes as well as about the time Josses during reversal
of the controis and shifting of the hot stock.
Chapter IV
EXAMPLES OF DESIGN AND CALCULATION

The folIowing examples of design and calculation may be used as a guide for
the design of forging press installations. The construction depends on the require-
ments and the prevailing operating conditions. However, the construction dimen-
sions and standard values as listed in table 23 should be aimed at.
Table 23. Standard ValvEs for Dimellsioning of Hydraulic Units
Extract from DIN-Standards. (AII dimensions are metric)
X ominal ram forceii COli sI rll<:! 1011,, 1 ,li m clls ions ') ::\0 111. pr e~5': . ~ O lll.dinm,
In k p o r )r". (St :lJul ard di I1 W11:-: iOtl:o\) in IlHII in k 'licm ' in mIII
F ig ll rcs rrom D IS :323 Vigur . rrom ))1 X :1 and DI X :12 ~ ,"ele ·t. r rom . ·clcct. r rom
Dl X 240 1 DI S 24 0~
U IO R.20 I l Ua R. 40 11. R. lUO S Il PP1. R 40

1.'li P!)). R. 110 I Ro R. li. R"
I
20 20/40 1 m lllCS \'illu cs 5
" 10 10 10 10
1 10 100 1000 10 100 1000 10 100 10 100

I 11
10 5 10 50
106 1060 106 ' 1 10 1060 1 100
112 1120 11 112 115 1120 1150
118 1180 118 1180 1200
J,25 ,12,5 125 1250 I 12 125 I 1 30 1250 1 300 125 12 125

132
14 140 I
I 150 I
1320
1400
1500
132 135
14 140 14 5
150 155
1320
1400
1500
1:350
1450
1550
I
1) Constructional dimensions include aII main dimensions, such as ram dia-
meters, stroke, daylight between the tools and the columns, column distances,
column diameters, etc.
The values as per DIN 323 Sheet 1 and 2 are to be preferred; the supplemcntary
values should only be used in exceptional cases.
13*
196 EXAMP LE S OF D ESIG N AN D CALCVLATION
Table 23 (continued)
Xom in:ll ram ro rcc COlls truct ionnl llimcnsion: ~ o m. press. XOIII.llinm .
in kp o r ~[p. ( Sta n,l:l rd l imcnsiolls) i n 111111 ill kll/cm ' in 111111
J"igurcs rrom Dl X 323 Figu re: rrum il I X 3 mul D LX 323 Sclcct. rro m 'cle t. rrolll
DlX 2401 DlX 2402
lHu R. B. 1140 ·uPI \. R4 0 ,' UllPI. Ra i R. U. Ra R. Ra
" "
1110 1 R20 1 }t40 20 20/40 10 10 10 1lJ
Ivalu ~ "Hlucs
1,6 16 160 1600 16 160 16;; 1600 ]6,:;0 16 160 lGO

170 1700 170 LiS 1700 1750 16
1
18 180 1800 18 180 1 5 1800 1 50
190 1900 195 1900 1950
190
2 I 20 200 2000
1'0 1 2(lO 210 2000 20 50
2100
200 20 200
212 2120 212 220 2120 2 150
2200
22 224 2240 22 224 230 2240 2250 I
2300
2350
236 2360 236 240 2360 24UO
,.5 I2.1 250

24 50
I 25 25 250
1
2,5 25 250 2500 250 260 2500 2600
265 2650 265 270 2650 2700
28 280 I 2800 28 280 280 2800 290U 1
300 I 3000 30 300 3 10 3000 3100

I
3,15 31 ,5 315 3150 32 315 320 3150 3200 315 32 315
335 3350 34 335 3:30 3350 3300
340 3400
350U
I 3~O
35,5 355 1 3550 36 355 360 3550 :j (IUO

;J700
1
;J70
:3 00
375 3750 38 375 380 3750 390t!
390
4 40 400 4000 4 1 40 400 41 0 4000 4 40 400 4 40 400

420
425 4250 430 4250
42 425 440
45 450 4500 4,5 1 45 1 450 460 4500
475 4750 48 475 4 4750
·]·90 I
1
5 50 500 5000 5 50 500 520 5000 1500 5 50 1
530 5300 53 530 f>50 5300 55UO
56 560
600
5600 5,5
6000 I
56
60
560
600
5 O 5600
6000
,
6,3 63 630 1 6300 6 63 630 650 6300 6500 6 63 630 6 63
670 6700 (17 , 670 700 6700 i UOO
71 710 7100 7 I 71 710
750 7500 75 750 7100
7500 1 I I
8 80 800 8000 880 1800 8000 00 8 80
850 8500 1 85 850 8500
90 900 1 9000 990 1
900 9000 I
, 9500 I
I 950 9500 95 960
110000 110000 1 ~
EXAMPLES OF DESIGN 197
a) Examples of Design
1. Press Cylimler with FiUing Valve of a Three-Stage Forging Press with
the Power Stages 2,200-4,400-6,600 tons (fig. 160)
Three identic al press cylinders of cast steel GS-45 are inserted into the top
platen_ A long bronze lin el' guides the ram, and sealing is effected by chevron
packing rings. The cylinder bottom is semi-spherical and made the same thickness
as the cylinder barrel for casting reasons and due to the large inlet bore. The
cylinder collar transmits the full ram load to the top platen and is flange-shaped
to receive the mounting bolts.
The prefill valve is of the vertical type which is generaIly preferred. For the
return motion of the press ram, the push-rod opens the prefill valve only a smal1
adjustable amount to limit the velocity. The prefill valve is wholly opened on
lowering of the press ram under air vessel pressure. The velocity is regulated by
the discharge from the return cylinders.
2. Steam Return Cylinder and Piston for a Steam-Hydraulic

2,750-ton Three-Cylinder Press (fig. 161)
Design as per steam engine specifications. Calculation of the return load - with
rcgard to the required discharge pressure in the press cylinders - as per the ex-
planations given on p. 63 et seq.
3. Moving Crosshead of a 1,150-ton One-Cylinder Forging Press (fig. 162)

In order to attain a low bearing pressure in the guide bushings when forging
eccentricaIly, the guide lugs are made particularly long (h"" 5 d). A high bending
stress in the moving crosshead occurs only when the crosshead hits the protecting
jackets of the columns. Assuming that this case seldom occurs, the section modulus
of the moving crosshead is determined such as to give a nominal bending stress of
ah ~ 1,800 kg/cm 2 maximum.
4. Basc Platen of a 2,200-ton Forging Press (fig. 163)

The platen height is calculated in accordance with the specifications given for
the cylinder platen (see example of calculation No. 6), the extension of the upper
fiange for receiving the shifting table being neglected for the calculation of the
section modulus.
b) Examples of Calculation
1. Main Cylinder of a 6,600-ton Three-Cylinder Press (as per fig. 100)
The cylinder is repetitively stressed from O to 2,860 psL
~: =u= !~:~~~ = 1.28; u 2 = 1.64

a) Rough calculation without considering influence of shape. Comparison stress at
the inner fiber (see formula table 2, p. 44, and fig. 36, p. 42)
sei = 2,860 ]13 ~:~! = 12,700 psi.

198 EXAMPLES OF DESIGN AND CALCULATION
i:==1~H--_....;1 1$15'f --+--tI779oi!
l' ig. 1GO l'rc ·s c)"lindN wilh Ilrcftll ntlH.

EXAMPLES OF CALCULATION 199
I'f80"
7JS
~
~
J
1200"
12.90"
~
~
I I ~
lQ
I 10J
I ::::
I '
II 1210~
-7.f(} ~
~
}'jg, 161. Stea", rct urn cyli ml cr wi t h piston .

J'ecfi(}{/ A-JJ
}'ig. 162. ~loving el'ossh('ad of a unc-ryliuder furging Vl'(':;;~.
Inflation strength of <:ast steel ASTM ;\-27 GR 60-30 8i, = 31 ,r;00 psi
Sp il;s = 31,5~0 = 2.5

8,.; 12,700
b) If - considering thc notch effcd - the following form factors are applie(] :
r:t. = 3 for the longitudinal stress 8 1 becausc of thc shouldcr at tlw
end of the liner and
eL = 1.3 for the tangential stress 8, considering thc casting surface,
then
13 '>8' 2.!î4 1-')
SI; = . X -, 60 0.64 = + :>",00
S"i = 2,8fiO
1
SI = 3 X 2,860 0.64 = + 13,400
Resulting in s"max = 17,300 psi_ _

31,DOO
Safety factor against fatigue facturc SF = -17)100· = 1.8.
,sec/ion C- j)
- ·270 - - - -.J/JJ -
1 .
~ ll
~~
I , _,o
- 00 - - uo,
The mounting bolts are equal for aU thrcc cylinders and arc dimensioned to
take - if the middlc ram is jamed - the filling pressurc on the two side rams, all
moving wcights and the wcight of the middle cylinder, decreased by the load of
the balancing rams.
Ram load and total weights 660,000 lbs.
Load of balancing rams 396,000 lbs.
-_.- --
Load on the bolts 264,000 lbs.

Chosen 12 bolts M 68 x 4, area at root of thread 4.75 sq. in., nominal tension stress
264,000 .
s, = 12 X 4.75 = 4,650 pSI.
202 EXAMPLES OF DESIGN AND CALCl:LATlOX
Cylinder shoulder (see fig. 40. p. 46): -

cylinder wall thickncss 8 = 61 / 2 in. (165 mm)
beginning of shoulder 8 1 = 71 / 2 in. (190 mm)
inclined length li = 97 / 8 in. (250 mm)
shoulder radius, smoothly machined and without grooves '! ~ 19 / 16 in. (40mm)
shoulder width w = 4 3/ 8 in. (110 mm)
bearing surface - taking into account the bolt holes Ai! = 850 sq. in.
4,400,000
bearing pressure at shoulder p = - 8.50 = 5,180 psi.
flange thickness h = 15 in. (380 mm)
Calculation as per DIN 2505 (see p. 47):
A 2 = 97 sq.in., P2 = 4 5 / 8 in. (11,75 cm)
S- 1 [2 X 97 X.
--uf 462'"0+-
46.5+7.5
H- (·.M5
,. 2 - 6.5
2
4 )]_800'
- 1Il.
3
Moment arm a = 711 / 16 in. (19,5 cm)

Form factor - for taking into account the machining quality - is chosen
(1.=1.5 .. ,2nX800X31,500
Safety factor agamst fatlgue frac turc S1 = 4~400,OOO X 7.G875 X 1..5 = 3.1.
2. Prefill Valve with Intensifier of a 6,600-ton Three-Cylinder Forging

Press (ac; per fig. 160)
Flow area as per the formula gained from experiencc (see p. 15ti)
AI = 0.05 Ali = 0.05xl,550 = 77.5 sq.in.
Chosen d l = 97 / 8 in. of A,z = 76.8 sq. in.
Push-rod = 21 / 2 in. of Arll = 4.9 sq.in.
AI = 71.9 sq. in.
A t a press ram lowering spced of v p = 1 ft.jsec. (0.3 mjs) the flow velocit~· in
1.550
the filling valve becomes v p = 1 71l} = 21.6 ft./sec.
Push-rod d1 /d 2 = 75 / 16 in./4 9 / J6 in. (185/115 mm)
Annulus area A, = 25.6 sq.in.
Push-rod force at 2,860 psi. 73,OOOlbs.
Spring load at end of stroke 5,800 lbs.
effective push-rod force P p = 67,200Ibs.
I"oading of the filling valve by the discharge pressure in thc press cylinder
(143 psi. above air vessel pressure) at 1]1/4 in. (284 nun) diameter of the
valve cone PA = 98x143 = 14,000 lbs.
\Vith the three-stage forging press it might occur that the return load acts on
the middle cylinder alone, creating a discharge water pressurc of p" =
3x143 = 429 psi. above air vesscl pressure. Therefore. a loading oi the
filling valve of PA = 98x429 = 42,000 Ibs. has to be rcckoncd with.
3. Shifting Table and Ejecting Device of a 1,270-ton Forging Press

(figs. 164 and 165)
Table size 110x63 in. (2800x1600 mm)
Thickness of table plate 77 / 8 in. (200 mm)
Total movable weights (table, lower die, and largest ingot) G = 88,000 lbs.
Motion resistance R = /-lG = 0.4x88,000 = 35,200Ibs.

Supplement for accelerating the masses 8,800Ibs.
- _.. _ - - - - -
required shifting force 44,000Ibs.
Chosen 2 rams for each shifting direction
Ram diameter d = 31/8 in. (80 mm), a = 7.8 sq.in.
Operating water pressure p = 2,860 psi.
Shifting load P s = 2x7.8x2,8GO = 44,000 lbs.
,sec/ion E - F
Jee/ion
C-D
Fig. 164. Base platen and shifting table.
Cylinders forged steel AISI 1035, d i = 3 9/ 16 in. (90 mm); do = 415/ 16 in. (125 mm)
do
-=u=1.39; u 2 =1.93
di 1.93
Comparison stress at the inner fiber Be i = 2,860x 1. 73 O 93 = 10,300 psi.
Yield strength for AISI 1035 By = 45,000 psi. .<
Form factor - taking into account changes of area and machining grooves -
is chosen rx = 2 8 45.000
Safety factor against fatigue fracture SF = -Sei·rx 10,300 X 2 = 2.1
Packing space 4 in./33/16 in. (100/80 mm) diameter, annulus area a = 4.42 sq. in.
Load on the stuffing box P St = 4.42x2,8GO = 12,600 psi.
Chosen 4 gland bolts M 24x2, area at root of thread al = 0.55 sq. in.
204- EXAMPLES OF DESIGN AND CALCULATION
12,600
Sominal tension stress at root of thread 8" ~ 4xO.55 = 5,700 psi.
CouplinlS pin between shifting band and table
Diametcr d p = 51/8 in. (130 mm)
Action of shifting load P~ at lever arm a = 3.12 in. (7,9 cm)
44,000 X 3.12 .
Nominal bending stress in pin 8/, = 13.1 = 10,500 pSI.
Shifting band 97/ s x2 3/ S in. (250x60 mm)
Tension strc8S in the section weakened by thc
pin hole
44,000 ..
8 ~ 6 X 1.83 = 4,000 pSI. nommal stress.
Ej ecting cy linder :
The ejecting force on presses for picrcing accord-
ing to the Ehrhardt-proccss is u8ually chosen
1/10 to 1/"0 of the press capacity.
Chosen ejccting force Pp; ~ 88,000 lbs. considcr-
ing friction and loading by thc return weight.
Diameter of ejecting ram d RII ~ !J3/ 8 in. (160 mm)
Operat ing pressure P = 2,860 psi.
Ejeeting cylinder do/d, = 101 / 1 in./63 / 1 in.
(260/170 mm)
Diameter of the ejecting rod d ~ 43/'1 in. (120 mm)
Diameter of the pun rods dl'R = 5'/2 in. (140 mm)
with thread M 100x4
area at root of thread a ~ 11 sq.in.
nominal tension stress a t root of thread
88,000 . .
8" ~ 2 X 11 = 4,000 pSI.
a
Heturn weight = 4,080 lbs.
Discharge water pressure upon re turn
Fig.l(ji}.
4,080 .
plJ ~ 31 ~ 132 pSl.
Hy<lr'l1Ilie eiecting <Ievi.:e.
4. Steam Intensifier for a 1,100-ton Forging Press

(fig. 166)
Operating water prcssure Pw = 5,720 psi.
Steam pressure Pe = 143 psi. (10 atm.), counter pressurc Pe ~ 8.6 psi.
Singlc press stroke 8 1 = 6 in. (150 mm), total stroke h ~ 47 in. (1200 mm)
Diameter of press ram d = 221 / 16 in. (460 mm), area A ~ 382 sq. in.
Pressure water rcquirements for one single stroke Ql = A 8 1 = 9.8 gal.
Additional rcquirements due to compression of the water Q2 ~ q Pw c
c = 3.i5x 10- 6 coefficient of compression for water including expansioll of
vessel (at 5,720 psi.)
q = ql + q2 + q3 with
ql "" 43.8 gal. press cylindcr volume at half thc total stroke
q2"" 9.3 gal. volume of piping
q3 "'" 10.6 gal. intensifier volume
--- -- -
q "'" ():~. 7 gal.

therefore, Q2 = 63.7x5,720x3.5xlO- 6 = 1.27 gal., and the required water
supply of the intensifier at one single stroke Q = Ql + Q2 "" Il gal.
Intensifier stroke chosen 8 2 = 551 / 8 in.
Area of intensifier ram a 2 = Q/82 = 46.5 sq. in.
Diameter of intensifier ram d2 =
7.675 in. with a 2 = 46.5 sq. in.
Intensifier force P 2 = a 2 Pw =
264,000 lbs.
P
Area of steam piston aa = _ _2 _ =
pe - Pa
1,975 sq. in.; with regard to flow
losses and mechanical losses the
diameter of the steam piston is
chosen
da = 51 in. with aa = 2,060 sq. in.
Steam piston force Pa = (Pe - Pa) a 3 =
133.5x2,060 = 275,000 lbs.
5. Hydraulic Intensifier for a

2,200-tOll Forging Press
(fig. 167)
Pressure intensification from 2,860 to
5,720 psi.
Press ram diameter d = 3F/2 in., area
A = 775 sq. in.
Total stroke h = 63 in. (1600 mm)
Single stroke at pressure stage of
5,720 psi., 8 1 = 6 in. (150 mm)
Volume of stroke at one single stroke
Ql = A 8 1 = 775x6 = 4,650 cu. in. =
~20 gal.
Additional water requirements due to

compression and vessel expansion
(see example 4) Q2 = q pc
ql"'" 110 gal. volume of press cyl-
inder at haU the
total stroke
q2 "" 23.3 gal. volume of the high-
pressure cylinder of
the intensifier in-
cluding the antici-
pated additional re-
quirements
qa "" 3.7 gal. volume of piping
q "" 137 gal.
therefore, Q2 = 137 x 5,720 x 3.5 x
10- 6 = 2.74 gal. ].'ig. 166. Stcam intcIlRifier.
206 EXAl\iPLES OF DESIGN AND CALCULATION
Actual water requirements for the

sing!e stroke Q ~ 20 + 2.74 = 23 gal.
Corresponding water requirements in
the low-pressure cylinder (2,8GO psi.)
5,720
Q,v ~ 2,860 Q ~ 45.1) gal.
Diameter of the low-pressure ram

chosen de ~ 153 / 4 in. (400 mm), ne =
195 sq. in., including the amount
to overcome the two return rams
of d H ~ 23 / 8 in. (60 mm) ar II /1 =
4.36 sq. in. each; thus the effedive
area of the low-pressure rams aL ~
195 - 8.7 = 186 sq. in.
Low-pressure ram load P L ~ lH(i;<
2,860 = 530,000 Ib8.
with 'YJ ~ 0.95 - with regard ta friction
and reciprocating weights - a force
of PJl ~ 500,000 lbs. is maintained
for the high-pressure ram. The
rcqllired high-prcssure ram area tn
r:' . " 500,000
create ,),720 pSI. 18 alI ~ ,- 720
87.5 sq. in. ,J.
Chosen dJ[ ~ 10 5/ 8 in. (270 mm) with

nlf ~ 88.5 sq. in.
Q fi 260
Ham strokc s ~ , ~ 8'" _ ~ 59 1 f., in.
aJl o.,> -
Discharge water pressnrc in the 1011'-
pressure cylinder
2 au •.
P" ~ .. X 2,860 ~ 130 pSl.
aL
Friction losses arc compensated by the

Fig, l(ji . H_ydraulic pre~surc inknsifieL weight of the moving components.
6. Cylinder Platen of a 2,750-ton Three-Cylinder Pres8 (fig. 168)

Designed as a box-type casting to obtain great rigiduess. For reasons of shaping,
and also ta euable maintenance personnel to walk an top of the platen in case
of repair work, the upper side is carried out parallel ta the plane of the lower side.
The height of the platen has been determined with regard ta a permissible
s
nominal bending stress of s". ~ --"-
s ~ 11,000 psi. maximum for ASTM A-27 GR 60-8
with a bending yield strength 8 y ~ :n,500 psi. Furthermore, it has to be noted that
the height of the column lugs is approx. h ~ 3.5 d (column diameter d ~ 17 3(6 in.
(440 mm).
Bending moment in platcn center 1ffb ~ Hll xlO G in.lbs.
Section modulus
for the tension fiber SI = 10,950 in. a,
for the compression fiber S2 = 10,380 in. 3
Nominal bending stress
in the tension fiber 8" = ]}f,,/Sl = 9,300 psi.,
in the compression fiber 8" = ]}fb/S~ = 9,800 psi.
Seclion A -A
8tJ.f H 8
.1
,, _____ ___ L
~ .1 ___ d.
950~ -
fllfO ~----
Sec/ion C-C
- - 'I{)O- - -3,,00 -
J.SJl.,-- 7Z0 - -
- - '100- -.
Fig. 168. Cylin<ler platcn of a three-eylinder prcos.
7. Columns of a 2,750-ton Fonr-Column Press (fig. 169)

Material AISI 1035
2,750
Column puII P , = -4- = 690 tons
Total press stroke h = 63 in. (1600 mm)
Eccentricity e = 65 / 16 in. (160 mm)
Stress calculation for point B as per the

rules on page 33 (for point A the sallle
loading as for point B is assumedl:
Column diameter d = 173/ 4 in. (450 mm), area
A = 246 sq.in., S = 545 in. 3
Nominal stress from column puII and bending
moment
5,500,000 5,500,000 X 6.3
8" = '4><246 + - - 4-X545
= 5,580 + 15,900 = 21,500 pSI.
Form factor (X = 1.25
8 m ax = (X 8n = 1.25 x 21,500 = 27,000 psi.
Safety Factor SF = ' 8y- -= 44,500
2-7 000 = 1.64.
8 1Ua x. ,
8. Air Vessel for a 6,600-ton Three-Cylindel'

Forging Press (fig. 170)
The welded air vessel of sheet steel ASTM
A-7 has a manhole in the upper end to ensure
accessibility without removing the piping. For
alI connections reinforcing rings are provided.
Total press ram area A = 4,650 sq. in.
Return ram area a = 410 sq. in.
Total stroke h = 118 in.
max.fillingvolume V p = (A - a) h = 2,180 gal.
max. drain volume V]) = A h = 2,380 gal.
}'jg. IG9. ColumllS. Internal diameter of air vcssel d i = 101 in.
with Aav = 8,000 sq. in.
2,180 .
Lowest water level at -35- = 62 / 2 111. bclow NW
1
Highest water level at 2,:~~ = 681/ 2 in. above NW

Pressure at normal water level (NW)PNW = 100 psig.
Required pressure at lowest water level P L = 70 psig.
As per fig. 171, for the isothermal change of state,
V x is derived from the formula : (2,180 + V x) 70 = 100 V x ; V x = 5,100 gal.
Air volume at highest water level V A = V X - V]) = 3,050 gal.
From the formula 100 V x = PH V A the water pressure at highest water level is
100 V x
Pll = -V~- = .
180 pSlg.
With an ample extra volume up to the discharge port and a· sufficient sump
of together about 3,000 gal., the total volume of the air vessel ia V T = 10,600 gal. =
4.87 V F •
The overfiow valve to the elevated tank is set for the pressure of the normal
water level (85 psi.), the safety valve for 170 psi.
Material of the air vessel sheet steel with
8 = 47,000 to 63,000 psi.,
8. = 26,000 to 33,000 psi.,
0= 27 to 22%
leslcodr
wole/' level,
lif/e fo con/rol
1
..,
~
I
Teslcock
woler
Line 10
F/oor
Aspho/l-coaled an insirJe, Anfi-CO/'IY./Jive pain! on oW,fide
14 )I.iU lcr, Hl'draulic For;:!i llg P rcsses

210 EXAMPLES OF DESIGN AND CAI,CULATION
Wall thickness of the jacket t ~ d02L~F + 0.04 in. ~ 0.61 In. (15,5 mm)
.8 q
0 ,
zo do ~ 102 in. outside diameter of the

flSi ~g
air vessel
p ~ 170 psi. max. pressure
150
150 1\ 8. ~
SF ~
26,000 psi.
Safety Factor with regard to
\1 yield point
'\
q~ 0.9 quality factor of weld seam
chosen t ~ 0.63 in. (16 mm)
t 100
">..
1\1 Sheet thickness t] of the upper tank
end with manhole
d . p' fi· SF
50 - + 0.04 in. ~ 3/4 in.
50 ~ ti ~ o 4
• 8 ,1 (19 mm)
with fi ~ 2.8, SF ~ 1.5,
I
/ Almospheric line chosen t1 ~ 0.78 in. (20 mm)
o Sheet thickncss of thc lower end t2 ~
00 0.52 in. (13.2 mm)
500 1,(J(KJ ru.fl. 1500
--- ~ ---.. .... JO -:-lfo with fi ~ 2, SF ~ 1.4,
- / f -I!, carried out tz ~ 0.71 in. (18 mm), tak-
Ţ
ing into account additional stresses
Fig. 171. Tsothermal change of toudjtion
of state. due to support by welded feet.
9. Power Water Station for a 2,200-ton AccuIDulator-Operated Three-

Cylinder Forging Press
Operating water pressure max. p ~ 2,860 psi.
max. stroke h ~ 63 in.
8 press rams of 26 in. diameter each
A ~ 8x530 ~ 1,590 sq. in.
2 return rams of 9 in. diameter
a ~ 2x64 ~ 128 sq.in.
Max. working velocity v ~ 4 in./sec.
a) Accumulator
The press stroke is layed out in conformity with the press size, no extra-
ordinary conditions prevail. Therefore the working volume V ~ 13 to 14 (A + a);
carried out: V ~ 384 gal.
Chosen water bottle of d i ~ 27 in., do ~ 89 in., l ~ 238 in.
Total volume of accumulator V T ~ 10 V ~ 8,840 gal.
Pressure after withdrawal of the working volume V:
P2 ~ P(.y V-;_V-r ~ 2,500 psi. with n ~ 1.3.
T
Lowering velocity V w of the water level in the water bottle:

internal cross-sectional area of the bottle Aw ~ 564 sq. in.
1,590 l'
V w ~ 4 564- = 11 14 In·/sec.
Diameter of the pressure water connection on the accumulator
d c ~ 43/ 4 in. with Ac ~ 17.8 sq. in.
STEAM- AND AIR-HYDRAULIC FORGING PRESSES 211
. 1,590
Discharge veloClty va = 4 --17.8- = 30 ft./sec.
Compressor drive = 8 H.P.
Amount of air drawn in: Qc = 530 cu.ft./h. V .
Time required for charging the bottles with air T = Q:~ = 170 hours
b) Feed pump8
Required delivery for cogging
n
Q = (A e + a h R ) - (see p. 121)
17h
A = 1,590 sq. in. (press ram areal
a = 128 sq. in. (return ram areal
e = 31 / 8 in. (penetration depth)
n = 21 min- 1 (number of strokes)
h R = 43 / 4 in. (return stroke)
17h = 0.9 (hydraulic coefficient of efficicncy of the press)
Chosen 3 pumps of 188 g.p.m. each = 546 g.p.m.
Piston diameter d = 2.8 in., a = 6.14 sq.in.
Revolution n p = 160 min- 1
Number of pistons i = 3
Volumetric coefficient of efficiency of the pump 17v = 0.95
. 106 • Q 43,500 X 10 6 •
Piston stroke 8 = = - - - - - - - - - = 151/ m.
6.14X3x 160XO.95
- - o- - - - -
P a ' ~. n p ' 17v 2

QeU = 3x 191 = 573 g.p.m.
Piston force F = 17,600 lb8.
" . np 8p 160X 153 / 4
Medmlll plston veloCIty c = -30' 103 =30>a03 - = 7 ft./sec.
188 X 0.1337 X 2,860 X 144
Output at crankshaft = -60X 550 xo.8--- = 390 H. P. for each pump.
Chapter V
ECONOMY AND COMPARISON OF THE VARIOUS

KINDS OF DRIVE FOR FORGING PRESSES
a) Steam- and Air-Hydraulic Forging Presses
Utilization of steam in a forging press instaHation is very uneconomi-
cal. The main reason for this is the fact that aH steam cylinders work
with fun pressure without utilizing the expansion energy. Particularly
prodigal is the steam operation for planishing, when the controls are
reversed for constant pressure (p. 179) in order to attain more strokes
per minute. In this case there is no difference between idle and working
strokes of same size, so that - for low penetration dephts - much more
energy has to be employed for the idle stroke than would be required
for the effective stroke.
Similar conditions - like for planishing - prevail for the return
device. It may occur that the return cylinders have to operate with
14*
212 ECONOMY AND COMPARISON OF THE V AHIOUS KINDS OF DRIVE
full pressure, although the very return stroke amounts to only a fraction
of the filling height. This uneconomy may be most clearly exprcssed by
an example.
Both return rams of a 2,750-ton forging press (see p. 199) - being
under a steam pressure of 110 lbs./sq.in. - have a diameter of 47 1/ 4 in.
and a stroke of 59 in. If, e.g. for cogging the largest ingot, a return stroke
of 12 in. follows a working stroke of 4 in. - the return rams, in their uppcr
position, should stiH be 10 in. below their highest position - the volume
below both rams at end of return is 97.82 cu. ft. This volume of stcam
weighs about 281bs. and generates in a turbine with a steam consump-
tion of 5.6 kg/kWh 1 ) 2.6 kWh of electrical energy. For thc same return
way, two hydraulic cylinders with the same return load and 3,000 psi.
pressure require about 6.9 gaIl. pressure water which is delivered by a
pump - as per the data on p. 77 - at an energy consumption of thc
motor of approx. 0.175 kWh. This gives an approximate ratio of 1: 15.
The comparison becomes even more unfavorable, ii the penetration
depth and the return stroke are smaller and if the steam losses due to
dead spaces in cylinder and piping, and condensation arc taken into
account. The ratio improves, however, as the forging operation con-
tinues and the cross-section of the ingot decreases, thus changing thc
ratio to 1: 8.5 if, e.g., the distance between the ram and its highest
position is increased from 10 in. to 31 1 / 2 in.
The comparison indicates that for larger steam-hydraulic forging
presses the hydraulic operation for the return devicc is to be aimed at.
If it is not possible to connect to an existing pressure line, it is recom-
mended to provide for the re turn device a separate power water station
which can also be used for operating the shifting and ejecting deviccs
and the filling valve.
In order to be independent from a water power station, the return
rams as per fig. 172 may be subjected to constant pressure and two ad-
vance rams be provided for the down motion which are activated by
pressure water from the steam intensifier. The return cylinders are
either connected to the steam line or to an air vessel of about 700 psi.
pressure. On these presses, only the amount of steam corresponding to
the actual return stroke is used for the return motion and indirectly
consumed in the steam intensifier which, therefore, is made larger in size
and provided with a controlled pressure water line to the advance
cylinders.
Steam-hydraulic forging presses are generally built as onc-cylinder
presses for capacities up to about 2,200 tons. For larger capacities either
the two-cylinder design with central stem guiding or the three-eylindpr
1) AEG-Mittcilungcn 192;3.
design (see fig. 46) are employed. The obtainable staging of press capac-
ity (see p. 187) with the latter design in conjunction with a selector
control does not essentially influence the steam consumption, since
214 ECONOMY AND COMPARISON OF THE VAHIOUS KINDS OF DmVJ<~
with thc one-cylinder design, the press load can also be adapted to il
decreased forging resistance by throttling the steam. Therefore, the
number of cylinders depends in most cases only on the width of the
cylinder platen, which should be narrow to allow for close-to-press-
center crane operation for the working of short ingots.
Pressure stages on steam-hydraulic presses, either by applying thc
three-cylinder design or by using a stage intensifier (p. 103), arc seldomly
I-_&- ",
I I
I I
I I Moin
'------''-++ - - - - + - - -IIVI I : condelMtlP
L _______ .;
... _------ .....J
I
~
I
~
" nden,sor plllflp

/l.ererve oii droina;e
Fig. 173. Circuit diagratn for a, boiler plant with accunnIlators for operati OI} of forging prpsscs and
for gcncrating electric current. (Rntho, Berlin.)
used, but ensure, however, an increase of the single stroke length corre-
sponding to the decreased press capacity, which is often desirable for
piercing operations.
For improving the coefficient of heat efficiency of a steam-hydraulic
forging press, the waste steam is further used, if possible, for turbines,
for preheaters of boilers and for heating purposes.
Fig. 173 illustrates schematically the connection of a press or hammer
plant to an accumulator. The existing forging presses are of 550, 660,
880,1,650,3,300,5,500, and 11,000 tons capacity. The boiler plant gener-
ates about 400 tons of steam per hour with a pressure of 460 psi. and a
temperature of 800 oF. The utilization of the boilers is uniform. The
presses and hammers being shut down, the condensation machine 1 with
a capacity of 25,000 kW serves for generating electric current. The tur-
bine 1 discontinues to run if the turbines II and III as well as the presses
and hammers operate. The turbine II is a back-pressure engine with a
capacity of 4,000 kW. The waste steam with a pressure of 200 psig. is
used for operating the presses and hammers and the high-pressure part
of the two-stage mixed-pressure turbine III which is also layed out for
4,000 kW capacity. The turbine III absorbes the waste steam of the
presses in its low-pressure stage and gives off steam from its high-
pressure stage to the heating system, if the amount of waste steam of the
presses and hammers is not sufficient.
The feature of the installation is the lack of any amount of pressure
drop worth mentioning. For balancing the variation of the medium
steam requirement serve two constant pressure gradiant temperature
accumulators. They contain cooled condenser water in their lower por-
tion and pre-heated boiler feed water in their upper portion. For pre-
heating, a certain amount of bleed-off steam .and back-pressure steam
of 200 psig. pressure is consumed. Upon increasing steam requirements
for the presses, the withdrawal of steam for preheating the water and the
water flow through the preheaters ceases automatically to make these
amounts of steam available for press operation; thus the accumulators
are discharged due to rising of the gradient layer between hot and cold
water. The effect of the accumulators is enhanced by turbine III, as the
large amounts of waste steam from the presses de crease the steam con-
sumption in the high-pressure part, while the output of the turbine
remains constant.
For balancing the short-time load peaks at each press stroke a
cushion or pressure drop accumulator is provided, the pressure of which
drops from 200 ta 186 psig. when being discharged. In order to avoid
a rapid drop of steam temperature when large amounts of saturated
steam are discharged, a superheater accumulator is arranged in the
pipe line, by means of which an average temperature of 482 OF can be
maintained.
As the waste steam of the forging presses is also intermittently dis-
charged - thus rendering impossible a satisfactory control of the waste
steam turbine - it is necessary to also arrange a pressure drop accu-
mulator in the waste steam line.
To avoid interruption of the steam feed to the heating system during
standstill of the forging presses, turbine 1 is provided with a controlled
point of withdrawal; moreover, two additional uncontrolled points of
withdrawal for the bleed-off steam for the boiler feed water heater
are provided.
If air is used instead of steam ta operate a forging press, the expen-
diture of energy is considerably lower. Tests on steam-hydraulic pres-
ses - which were activated with cold air - have shown that, under the
216 ECONOIVlY AND COlVlPARlS0N OF TUE VARIOUS KINDS OF DRIVE
assumption of equal pressures, an average consumption of saturated

steam of 2,2001bs.jhour corresponds to a volume of air drawn in of
350 to 450 cu.ft.jmin. If it is also assumed that with large piston com-
pressors for pressures up to 135 psig., 1 kWh of electricity will comprcss
350 cU.ft. of air and that, on the other hand, 1 kWh are generated by
12.31bs. of steam in a turbine (p. 212), a ratio of 1 :2.2 is obtained when
comparing the two performance figures.
The uneconomy of steam operation as compared with air may
chiefly be traced to the high cooling losses at low-rate operation, stand-
stiH periods, change of shifts, freezing weather, etc. If, for instance, the
temperature of a compressed air volume of 3,500 cu. ft. at 115 psig.
pressure is 122 oF and it drops down to 59 oF, the volume is decreased
according to the equation VI: V2 = TI: T 2 to 3,100 cu.ft. On the other
hand, 2,200 Ibs. of saturated steam of 115 psig. pressure correspond to a
volume of 7,700 cU.ft. at.a temperature of abt. 346 oF. On cooling down
to 59 oF, the 7,700 cu.ft. of steam change to a condenser volume of
35 cU.ft. The decrease of volume, therefore, takcs place by the ratio
of 100:88.9 for air and 100:0.455 for steam.
The volume of air can stiH considerably be increased by heating
with the exhaust gases from the annealing furnaces. Oil-containing
compressed air, as supplied by piston compressors, may be heated up to
about 350 oF. Thus - as per the afore-mcntioned equation - an increase
of efficiency by about 40% is obtained, assuming a constant pressure,
and if the operating temperat urc is assumed to be again ]22 oF. OiI-free
air by turbocompressors may be superheated to 482 oF, thus achieying
an increase of efficiency by 60%.
By utilizing waste steam in turbines the economy of the steam op-
eration is improved. For 1 kWh about 36.5Ibs. of waste stcam of 1.5 psig.
pressure is required. Without superheating the uir, the ratio of the
consumption figures is reduced about 1 :1.5. It is suitable - as shown in
fig. 173 - to arrange a waste steam accumulator before the turbine.
If the waste steam can bc utilized in a heating plant, thc steam
operation becomes more economical than air operation due to recuper-
ation of the heat of vaporization. For this reason installations havc
been carried out which are operated with compressed air in summer and
steam in winter. Thereforc, the pipe lines are providcd with change-
over valves.
b) Forging Presses with Accumulator Operation
Originally there was great aversion against the accumulator op-
eration as long as one was dependent on weight accumulators, the draw-
backs of which are described on p. 115. In addition to the bad experience
which had been made with these accumulators in forge plants came
FORGlNG PRESSES WITH ACCUMULATOR OPERATION 217
the arduous shifting of the press controls which resulted in premature

tiring of the operator. Another drawback was the considerable space
rcquirements of the pump drives which had - instead of gears -
flywheels of 12 to 15 ft. diameter at an output averaging 300 to
400 H.P.
However, the conditions changed basically after the power water
stations had been improved considerably, mainly by introduction of the
compressed air loaded accumulator and by changing the controls which,
today, can be operated just as easy as steam controls. For this reason,
the accumulator operation has been given preference for about 30 years
now for new plants, and in many cases steam-hydraulic forging press
installations have been converted to accumulator operation.
The power water station is suitably separated from the press and
placed in a separate engine room. It may easily be expanded if the press
plant is to be increased and used as group drive for several presses.
Generally, in this case considerable costs can be saved, as generally alI
presses do not operate simultaneously. In case of large distances to the
individual presses it is suitable to place the accumulator partly or
wholly adjacent to the points of consumption, that is to locate the indi-
vidual water and air bottles directly at each press while the pumps
remain arranged centrally. The pumps may then be controled by the
central accumulator or remote-controled by the individual consumers,
for which the electricalIy actuated control gears are particularly suitable.
In this case the hydraulic connecting pipes are provided with relatively
small flow areas, as they are not any longer layed out for the pressure
water peak demand, but for the considerably lower medium water con-
sumption. This arrallgement also eliminates water hammer and makes
shock absorbers unnecessary.
The advantage of the accumulator operation is its wide adaptability.
It permits any practic al press velocity and the performance of largest
lengths of stroke, thus improvillg the economy by decreasing the forg-
ing time. When forging with large cogging strokes, on one hand, the
press does not have to perform a certain single stroke, and on the other
hand, no dead cycle time arises for fillillg the dead space during planishing
operations. The folIowing example may be given: for cogging an ingot,
weighing 38 tons, to produce a column of 20 1 / 2 in. diameter and 62 ft.
length under a steam-hydraulic 2,200 ton forging press (fig. 47), seven
heats were required. However, only five heats were necessary after the
press had been converted to accumulator operation.
The operation costs of the steam operation may best be comparcd
with those of accumulator operation by carrying out the same operatious
under two presses of equal capacity aud with the two different operating
media aud recordiug the consumptiou of current aud steam. The indicated
218 ECONOMY AND COMPARISON OF THE VARIOUS KINDS OF DRTVE
prerequisites, however, are seldom found in a forgo plant, while the

values of the various plants usuaHy include great inaccuracies. There-
fore, one puts up in most cases with a theoretical comparison.
If it is assumed, for instance, that with a 2,200-ton forging press
10 single strokes of 4 in. penetration depth are to be carriod out, the
steam consumption would amount to about 800 cu.ft., presuming that
the steam pressure is 150 psi. and that the steam piston of the intensifier
of 59 in. diameter performs a stroke of 51 in. The return uevice consumes
an additional 340 cu.ft., the two return rams having a diameter of
34 1/ 2 in. The very return stroke is assumed to be 8 in., while the volume
of stroke oorrosponds to a return stroke of 31 1/ 2 in. The total stoam
consumption amounts to about 1,440 cU.ft. or 500 lbs. at 150 psi. prossure,
taking into acoount the coefficient of efficiency of 1] = 0.8 for losses due
to dead spaces, compression of the water, air occlusion, elongation of the
press, and leaky points. As per the data on p. 211 this steam consump-
tion in a turbine corresponds to a generated current of 40 kWh.
The consumption of pressure water for the same operation is roughly
380 gall. at an operating pressure of 3,000 psi. and a coefficient of effi-
ciencyof 1] = 0.85, resulting in an energy consumption of 10 kWh. Thus
the expenditures for energy in the form of electric current and steam
are in a 1:4 ratio.
However, if the return device of the steam-hydraulic forging press is
activated by pressure water, this ratio changes to 1: 3.
All comparisons are made undeI' the assumption that for over-
coming the forging resistance the fuU press capacity is required. This
assumption, however, does not hold true for most forging operations.
As the steam pressure, however, may be adapted to a uecreaseu forg-
ing resistance by throttling, while with accumulators the fuU accumu-
lator pressure has to be applied for aH operations, a considera bIe impro-
vement of the condit,ion in favor of the steam-hydraulic operation may be
anticipateu, so that the latter is possibly cheaper than the accumulator
operation.
It may be concluded, therefore, that in case of low forging rcsistance
undeI' an accumulator-operated forging press the input energy could be
a multiple amount of the effective work, resulting in very bad efficiency,
if the pressure is not fully utilized. Therefore, in order to in crease thc
economy when forging light parts, accumulator-operateu presses with
large capacities should always be of the three-cylinder design (fig. 174)
and provided with three different pressure stages. Two-cylinder presses
with central guide shaft do not permit such pressurc staging.
Very good experiences have been made with three-cylinder prcsses in
Germany. They are narrower than the two-cylinderpresses; the headroom,
however, is larger due to the long column bushings for guiding the moving
FORGING PRESSES WITH ACCUMULATOR OPERATION 219
crosshead. There are values of experience to the same effect regarding the
service life of the ram packings, when presses have been compared the
rams of which transmit the forging load through pressure rods to the
crosshead. It is also possible - as per fig. 51 - to arrange a central stalk
guiding in a three-cylinder press, if the pressure stages are such distri-
buted that the stalk can
be placed in the central
ram; the drawbacks of
this arrangement, how-
ever, are an increased
width of the cylinder
platen and increased
bearing pressure on the
liners in the middle
cylinder.
The one-cylinder press
with accumulator and
pressure intensifier for
two pressure stages can-
not be recommended for
new installations. Its
initial cost is higher than
for a three-cylinder press,
and there are only two
pressure stages instead
of three. Moreover, the
high-pressure stage per-
mits only limited single Fig. 174. 6,oOO·ton three·cylinder forgillg prcss with accumu·
strokes, the number of lator operatioll. (By: Hydraulik, Duisburg.)
strokes per minute being
slightly lower due to interposing of the intensifier. This arrangement
is only considered for converting steam-hydraulic forging prcsses for
accumulator operation, if one-cylinder presses with an operating water
pressure of 5,700 to 7,200 psi. are concerned.
Forging presses, where centrifugal pumps are used - instead of
piston pumps - for charging the accumulator, have not been employed
in Germany so far. Centrifugal pumps are relatively seldom used - despite
their low initial cost and in spite of their maintenance being considerably
cheaper than with piston pumps - because of their bad efficiency which
is seldom above 70% due to the required pressures and deliveries for
press operation. For comparison: the coefficient of efficiency of piston
pumps is about 90%.
There are examples of application of centrifugal pumps from U. S. A.
220 ECONOMY AND COMPARISON OF TIIE VARIOUS KINDS OF DHIVE
It is known from publications 1 ) that, e.g., a 1500-ton

, forging press with
three centrifugal pumps arranged in series operates there , which works
with three pressure stages, the difference of pressure between each
stage being 1,900 psi. and a pump rotating speed of 3,600 r.p.m. each.
c) Direct-Driven Forging Presses

The superiority of forging presses, directly driven by pumps, aver
the accumulator operation consists chiefly of the decreased energy
consumption to the actual work performed by the press. Even if it is
}'jg. 175. Pllll1]l ullits for the direct drive of a 1,500·(nll forging press. (B~' : Dnvy 11r8. U<t., R""ftiPl<l.)
compared with an accumulator-operated three- cylinder press with

three pressurc stages, the saving of energy is still considerable.
While in the U . S. A. and in Germany for the past :30 years accumu-
lator operation has been more and more employed, the direct pump
drive for forging presses (fig. 175) is stiH largely given preferenee in
England. The reason for this is partly the fa et that they remained with
the two-cylinder design with central stalk guiding with particular
prejudiee. However , this construction is not suitable for accumulator
operation as it does not permit economical pressure staging simil ar to the
three-eylinder press (see p. 187).
Another important feature is th e avoidanee of a constantly pressurized
1) J. Iron Stecl Inst. 161 (1949) March.

DIRECT-DRIVEN FORGING PRESSES 221
plpmg net which demands careful maintenance and which, in many
cases, has considerable losses of pressure fluid due to leaky control gears.
These indicated advantages of the direct pump drive, however, are
confronted with the fact that the pumps are of considerable sizes al-
ready for relatively low working speeds of the press. The working speed
for three-cylinder presses with pressure staging is increased by the same
amount as the forging load is decreased. However, a drawback of
direct-acting pumps shows up when pressing slowly, e.g. when upsetting
an ingot, as a part of the pressure fluid delivered by the pump has to be
Fig. 176. l,100-ton forging press with direct oii pump drive. (By: The Hydraulic Press
Manufacturing Co., Mount Gilead, Ohio.)
discharged through a relief valve, if no variable pump is provided for or

if the delivery cannot be split up an several disengageable pump units.
Moreover, very large strokes cannot be carried out in one single stroke,
since in this case the stored energy in the flywheels would not be suf-
ficient to meet the power requirements.
As far as the pump drive is concerned, it seems to be simpler and
cheaper than the accumulator operation at the first glance. It has to be
taken into account, however, that usually the pressure fluid for the
returns, shifting device, lift pulley, servomotor, etc. is withdrawn from
an existing line. If a separate power fluid plant shoula be r~quired for
operating these auxiliary devices, the initial cost for lhe accumulator
plant is - as a rule - lower.
222 ECONOMY AND COMPARlSON OF TIIE VARIOUS KINDS OF DRIVE
The direct drive with oiI pumps which has proved itself for a long
time on presses for cold working, has found application also in hot work-
ing plants. As oiI pumps permit a rugged design due to the special
characteristics of the oiI (see chapter "Pressure Fluids") and high
rotating speeds so that the drive can be coupled directly to them without
a reduction gear, the initial cost as well as space requirements are essen-
tially lower than for pressure water pumps. Fig. 176 shows a 1,IOO-ton
Fig. 177. 385·ton [orging press with crank gear illtcnsificr. (Ey: Hydraulik, Duisburg.)
forging press, with two oiI pumps of the radial piston design which arc
mounted laterally at the cylinder platen and which are directly coupled
tO the motors. However, this design has not proven; therefore, oil-
operated forging presses are nowadays generally carried out in the
inverted press design only with the pumps being arranged undeI' floor.
Besides pumps with constant delivery, also variable-delivcry pumps
are employed which permit selection of a certain delivery corresponding
to the motor output, e.g. for press operations extending over a longer
period of time.
DIRECT-DRIVEN FORGING PRESSES 223
Generally, careful maintenance of the oiI pumps and the oil-carrying

components in forge plants is not always possible. In order to fight the
results of leakiness - contamination, destruction of concrete foundations
and fire hazards - the press cylinders and the oiI units are nowadays
preferably arranged under floor.
The rack- and spindle intensifiers 1) described on p. 112 et seq. are
known as single units only. They did not find general application as
6.MO'r------,------~------~----_,------~
·wJ r-______+-______~------_+--------~----~
BTU _}feuml?J-drul/lic 720 -100 press Sfeum;y,tiruiJliC os per VOfh
~,OQ, ~ ----0- ----0-
I
560 Ion pre~ wifh
, ___~
~+~u~rr~/Jm
~ u~~W__~______-4__~~S!~~um0vtiroiJhc
~~
2,000..- ~ .•. -t... ... ..... 72~treo5$"-
" -1;. -- ,._, ... Z- Ion Colduirhommer 1 ---
~
" ",
+ - "- ~ .,
'"+1'---
iI,Q,OIOI--- 2-ton Hol uir hommer--------+--------+---------<
~ 800 I
3 .1
~ 5(}(} 'r-----<::: Pr= wdh crunkIJeor inlensifier --I~------+-------_
~ "'- us per POEh
1;;
; '0... ....
~ 4M'~---+--~~+_----+_------+_------~
1-- - - - - 550 -ton press wilh crunk geur 4---------4----------j

.....x · t-. inlensifier
'_X
2(}1m-______-+____x_.~
-~-xx~.~ x---~--------+_------~
._
550·100 press wilh cronk
-··t·_·-..
!leur inll!nsifler
IM'L-_ _ _L-_ _ _ _~_ _ _J __ _ _~~~._~

Z J ~ 5 5 lonsjh 7
Prodl/elion
Fig. 178. Consumption of energy when forging round" (as per working analysis of
Dortmund-Hiirder Hiittennnion).
Ilgner-systems are required for their operation with very high initial
cost. However, these solutions are remarkable, if one considers that the
Ilgner-system may also be used for operating a rolling mill, like e. g. in
case of the 6,600-ton forging press .plant. Tests which have been carried
out to provide a drive with standard electromotor and clutch have not
been successful as yet.
Forging presses with crank gear intensifier (fig. 177) have been carried
out in the single frame and in the four-column designs for capacities
1) Comptes Rendus des Journ6es de la Grosse Forge, Paris, 27-29 Mai 1948.
224 AUXILIARY MACHlNES FOR FORGING PRESS INSTALLATIONS
from 110 to 1,650 tons. Due to the sinosoidal press ram movement
- during the automatic operation - which requires no controls and which
is typical for the crank drive, any number of strokes may be chosen,
making these presses particularly suitable for forging operations ~with
many consecutive strokes of same size, e. g. for working of rods, shaftfl,
drums, rings, etc., largely relieving the press operator. The machining
allowance of the work pieces may be kept very small, as any deviations
of the end position of stroke arise only by increased "breathing" of the
press during progressive cooling of the work piece.
Under a 400-ton single-frame press, for example, shafts of Cr-Ni-
steel have been forged down to a diameter of 5 and 6 in. respectivcly, at a
length of 71 in., from an 7 1/2 in. square ingot, with a machining allow-
an ce of 5/32 in.; the deviations in diameter were only 0.040 to 0.060 in.
The particularly low expenditure of energy of presscs with crank gear
intensifier, as compared with accumulator-operated or steam-hydraulic
presses, may be noted from fig. 178. Herein, the power-heat consump-
tion per hourly output by presses with different kinds of drive and by
ham mers are compared, with same operating conditions prevailing; the
energy equivalence of 1 kWh= 4,000 kcal = 8.8Ibs. of steam was uscd
as a basis corresponding to the actual consumption of energy generated
by the plant. For comparison purposes, the values from "Anhaltszahlcn
fur die Wărmewirtschaft in Eisenhuttenwerken"l) are also plotted.
Chapter VI
AUXILIARY MACHINES FOR FORGING PRESS

INSTALLATIONS
Auxiliary machines for forging press installations are: cranes,
electrically activated turn-over and rotating devices, grippers, mani-
pulators, and auxiIiary tooIs.
a) Forge Cranes
For turning over or handiing the ingot usually two cranCB work
together (fig. 179). From their hooks suspend a pulley with single link
chain and a turn-over device. The turn-over device is electrically activated
and rotates the ingot with the heip o.f a bank chain.
In order to render possible handling and rotating of even short
ingots undeI' a press, it is necessary to enable the two cranes to move as
closely to the press as possible; the ciearance between the two cranes
1) Anhaltszahlen fiir die Wărmewirtschaft in Eisenhiittemverken, 5. Aufl.,
DiiRseldorf: Verlag Stahleisen 19:}7, S. 2Bfi.
FORGE CRANES 225
Fig. 179. Forge erane with two trolley earriages traveling on paralle! frames. Lifting eapacity of main
carriagc 220 ton" of anxiliary earriage 55 tons. (By: Demag, Dni,burg.)
Fig. ] ..,0. "Forging eralJ('~ witlI nwill and auxiliary troIlry and SulaU clearancc lJctWC<'1l the rrmws.
(Bl': ])clllag, Duisburg.)
e ,I I. \ \
l ,\
..L.
I
;
l<'ig. 181. Installation of a eranc in thc exist ing Imil!ling for a 3,300-ton forging Jlress.
15 .Nfiillcr, Hydrnlllic Forging J'rcsses
226 AUXILIARY MACHINES FOR FORGING PRESS INSTALTJATIONS
---;ipeed Drive Motor

Capacities l ft. / ~e c .
capacity
H.I'.
,pecr!
f.p.m.
emn e trave! I 200 150 7GO
I carriage
Lifting 165 ton~ 11 t/2 lfH 000
Crane
165/ 3:{/3:J tOIlS
l\faill earriagc
travel
I ]00
I 2:3
I 72r:i
I
_.\uxi1iary carringc
I
Ufting 33 tOIlS
carriagc travd
I
40
100
I 109
;),5
j
i\OO
750
I eranc tmvel
I I 200
I 100
I 750
)Iain c<lrriage j Lift,ing 88 tOIl S 14 IO\) (\00

erane
88/ 22 to ns
carriage tra\'d
I lOU j
];.
j
7];;
I
Auxi1iaJ'y carriage jl'iftiU g 22 tons 47 100 750
ca ffjage trnTel
I !OU 5,5
I n[)o
} 'jg. 182. Arrallgement of cranes in a, forge sho}) with fi, 6,60U·ton forging: press. Sidc yjC\v: milli1l11l1l1
elearallcc bctwccll tlte erane hooks. General Jllan view is sealed uOWll.
FORGE CRANES 227
depends on the dimensions of press and turn-over devices. These require-
ments entail crane designs which deviate from standard overhead
cranes. Further deviations occur through the safety devices which
prevent the transmis sion of the forging load to the crane framework. For
this reason the ropes are flexibly suspended and the turn-over device is
elastically seated on the crank hook. Moreover, the lift brake is adjusted
such that the brake disengages automatically when overloading, the ingot
being lowered slightly until the overload is compensated.
/) - - - - - - -.25200-
J;'ig. 183. Armngcmcnt of crane" for a 11,OOO-ton forging press. (By: Demag, Duislmrg.)
A suitable crane design is illustrated in fig. 180. Both forging cranes

are of same capacity and travel on a common track. The required small
clearance between the cranes is attained by retraction of the wheel
carriage under the main girders and by special design of the trollcy
carriages. Thus an extraordinarily small gap between the two main
hooks is achieved inspite of the large crane carrying capacities.
Another solution, which was rendered difficult by the installation of
a forging press in an existing building and by using the existing cranes,
is drawn in fig. 181. The track a of the small crane is located slightly
above track b of the large crane to enable the small crane to travel over
the end support of the large one. The longitudinal girders of the large
15*
228 AUXILIARY MACHINES FOR FORGING PRESS INSTALLATIONS
crane are seated on the end supports in order to provide the small
crane with a close approach. Both cranes are operated from an elevated
control pulpit which is located above fioor close to the prcss. Hence thc
cnme operator has an unobstructed view of the ingot and press.
Fig. 182 shows a particularly suitable crane installation in conjunc-
tion with a 6,6 00-ton forging press. As shown in the scaled down general
~ i i
~ I I
j i
i I
I 1
i ..\
J
4-J
*it
I
'ji
l·'ig. lS4. Ovcl'hearl cnmcs for a l(i,OOO-tOIl forging ]>I'pss. (13y ~IAX, )"iirnher~. Z. V in 19:J:l, Kn. 4;;.)
top view of thc building, two main cranes with one auxiliary cranc cach
travel on the same runway. With a span of 65 ft. one of the main cranes
has a trolley carriage of 165 tons and an auxiliary trolley carriagc of
33 tons lifting capacity, which travel independently of each other on main
parallel girders respectively, while the second main crane is similarly
provided with trolley carriages of 88 and 22 tons lifting capacity. The
main specifications of the cranes may be noted from the chart; the side
view shows the two cranes in their closest position to each other, thc
distance bctween the two main hooks bcing 13 ft.
Fig. 183 shows schematic drawing of crane arrangemcnt for a 11 ,000-
ton forging press. Two main eranes with a lifting capacity of 220 tons
ROTATING AND GRIPPING DEVICES 229
each move on a common truss. Above the two main cranes moves an
independent auxiliary crane - with a lifting capacity of 110 tons - which
is operated from the control stand of one of the main cranes.
Fig. 184 illustrates two cranes for a forging press of 16,500 tons
capacity. Each crane has a carriage of 330 tons lifting capacity at a
span length of 100 ft. Alongside the main carriage - on a paraUel truss -
JO(){}{)- - - - -- II
Fig. 18&. Arrangelllcnts of cmne carriages as ]ler fig. 184.
moves an auxiliary carriage of 110 tons lifting capacity which is used

- among other things - for discharging the furnaces and transferring
the ingots to the press. The cranes may also be operated Irom the low
operator's cab at the moving crane truss or - as occasion demands -
from a stationary control pulpit.
The auxiliary carriage, which was in former times frequently com-
bined with the main carriage, travels - with modern constructions
(figs. 182 and 185) - on a separate runway paralIel to the main carriage.
Hence this carriage may be employed for transportation of smaUloads,
and the small hook can be used independently of the big one for auxiliary
forging operations and for rotation of the ingot.
h) Rotating and Gripping Devices

Fig. 186 shows an electrically activated rotating device for sus-
pending from a crane hook. It is provided with spring-cushioned sus-
pension eyes to absorb the shocks during rotating and forging. The cali-
bratcd chain is madc of high-strength steel with regard to the great
heat. The chain pulley is driven through a double spur- and a worm
reducing gear by a standard motor; the current feed is effected by ,1
flexible cab le which is coiled and uncoiled automatically from a cable
reel mounted on the carriage. In order to prevent overloading of the
rotation motor if the ingot should suddenly be held by the press, the
gear is provided with a slipper clutch. Furthermore, the ingot can be
230 AUXILIARY MAClIINES FOR FORGING PRESS INSTALLATIONS
Sec/ibn ll-.b
1----l~O - View "A'
I
._.+- .-
I
----+---
JI-------------I~lb~~~i
-Fig. 18G. Elcctrical rotating de vice for Hi tons lifting capacity. (By: Dcmag, DublJ1lrg.)
held in any position by means of an

electromagnetic gear brake. The illus-
trated rotating devicc for a lift ing
capacity of 16 tons has a drive motor
of 12 H.P. output at 950 r.p.m. 1'hc
gcar is designed for a chain velocity of
about 28 ft.(min.
Grippers ar tongs for handling ingots
are also suspended from a crane hook
and provided with either a manual ar
automatic latch. In latch "in" -position
as per fig. 187 the tongs are opened. If
:\<'ig. 187. Tongs with latch for manual
operatioll. (By: Bonnhoff, Wettc r / l~uhr.) they are put on an ingot, the latch can
FORGING MANIPULATORS 231
be raised easily (fig. 188). Upon lifting the crane hook, the jaws are closed.
The be11 cranks are made of sheet steel and provided with a through
Fig. 188. Shop pilota of tongs as per fig . 187.
pin a. Each lever b is connected to the adjacent lever C only by a

pivoting pin d. Tongs which are to carry out reversing or raising of the
ingots, are provided in their jaws
with easily exchangeable mushroom-
. g
shaped points e.
Fig. 189 shows tongs with au-
tomatical trigger device for the
latch. The latch motion is effected
by a link slide block in cylinder f.
If point g is slightly raised or
lowered, the latch performs alter-
natelya sma11 and a large up and
down motion which is controlled
by slot h.
The lifting capacity of the largest
:Fig.1S9. 'rongs witil latch for automatic
tongs is about 165 tons. operation. (By: Biinnhoff, Wettcr/Ruhr.)
c) Forging Manipnlators
For the manufacture of turbine and generator shafts, vessel and
crank shafts, columns, axles, etc. manipulators are particularly suitable
which grip the ingot by tongs, shift it during forging operation in longi-
tudinal and lateral press directions, raise or lower it into the correct
232 ATJXILIARY MACHINES FOR FORGING PHESS INSTALLATIONS
elevation and reverse OI' ro tate it around its own axis. This demands a
certain resiliency in the tongs head if the forging tools re strict the mo-
tions of the ingot. The ability to control the velocity of an motions
precisely, and to stop OI' reverse instantly, must also be providcd for.
There are two different manipulator designs: the mobile and the
track-bound machines. The first design is usually adopted for small ingots
"Fig. HlO. Shop photo of il model 40-lllt llwnil)111a.tor o}lprating at u 2,'iGO-tUIl forging pl'e~s.
( C ourtp~~T : l\:.TuJlp, E~~ e n. Ey: Hydraulik, Duî:->hurg.)
which arc removed from the fumace by the manipulator and carricd to il
storage site after forging. 'Vhen adopting the IaUer design, a cmuc
installation is a pre-requisite for handling thc ingots, which must always
be available for the versatile use of a forging press and thus furthcl'
increasing the manipulator capacity.
The mobile manipulator as per figs. 191 and 192 runs on four wheels
with rubber tires, the real' wheels being driven electricalJy and which can
be swiveled by up ta 90° for steering the manipulator. In the main frame,
a lifting frame is elastically snspended which carries thc tuming spindlc
with the fianged tongs. The lifting frame can be rai sed and lowered par-
allei to fioor by means of a pivotcd lifting cyIindcr, while 1,he tuming
spindle can be tilted vertically by the help of tilting cylinders. The electric
drive of the turning spindle is layed out for two rotating speeds and
protected against overload by a friction clutch. The cylinder for hydrau-
lically activating the tongs closing device is arranged in the turning
spindle.
f--- - - - - f - - ---i
Fig. 191. MolJile forging manipulator. (By: Dango-Dienentlwl, Siegcn.)
j<·ig.192. 8hop pilota ofa mobile manipulator of 17,000 lhs. capacity. (By: Dango-Dienenthal, Siegl'lI.)
An electricalIy driven pressure pump supplies 60 atm. oiI for the

tongs closing cylinder and the lifting and tilting cylinders. Electricity is
supplied to the unit through a constant-tension cable re el. The mani-
pulator may also be self-contained by providing a Diesel-generator unit
(see fig. 192).
The main dimensions and special features of mobile manipulators
as per figs. 191 and 192 may be noted from table 24.
Table 24. Main Dimpnsions of Mobile Manipldators

as per figs. 191 and 192
ominal caITyiog capacity W Ibs. 2,200 5,500 1l ,OOO

Tiltiog moment TV·f ft.-Ibs. 22,000 55,000 Il 0,000
Gripping range } m ax . dlo. in. 18 1/2 21 1/2 27
of tongs mi •. d ia , in. 43/4 8 17
Lowest position of toogs g in. 271/~ 31 291 /2
Vertical displacement
of tongs II, in. 15 19 18
{ traveling ft·/ min. 230 197 197
Speeds liIting, max _ in./sec. 51/~ 4 1/4 3 1/ 4
rotating r .p.m. 18 7 and 14 7 aod 14
f traveHng kW 12 21 30
Motor capacities l oiI
rota.ting
pump
kW
kW
4
20
Il
29
Il
43
in. 203 247 291
Main dimension
r ~ in.
in_
in.
99
114
40
123
118
73
123
160
70
I~
in. 11 118 Il8
o 11
12 14
o 4
9 6
Figs. 193 to 195 illustrate a track-bound manipulator for ingots

weighing about 14 tons . With the help of a supporting rotary chain on the
opposite press side even heavier ingots can be forged. AH motions of the
machine are clectricalIy activated. Only opening and closing of the
tongs are effected by an aiI' piston which is arranged bchind the turn ing
spindle. The air cylinder is connected to a stationary compressed-air
plant by hoses. AlI shocks occurring by the press are absorbed by springs
in vertical as well as in horizontal direction; furthermore, friction
clutches which yield to overload are provided in the gears of the turning
spindle and the wheels. The lifting de vice of the manipulator permits
parallel up and down motions of the tongs; moreover , a tilting position
of the tongs in the vertical and horizontal plains is possible. The turning
spindle can operate with four different speeds and has two drive motors.
The operator's pulpit is arranged laterally on the frame ta enable the
operator to exactly check the elevation of the ingot and to facilitate
communication with the press operator.
Fig. 196 shows a steam-

hydraulic 1,100-ton forging
press in conjunction with
two track-bound electricaUy
activated manipulators. This
-1
arrangement is suitable, e. g., \
when forging axles to ensure ~ 11 .
continuous production. The
second manipula tor grips the
finished end so that the
ingot does not have to be
\ .
reversed.
On the track-bound aU-
hydraulic manipulators as
per figs. 197 to 200 the pres-
sure water for the working
cylinders of aU motions is
taken from an accumulator
which consists - depending
on the manipulator size -
of one or two verticaUy ar-
ranged water bottles for a
pressure of about 750 to
1,500 psi. and a number of
air bottles which are ar-
ranged - in order to sa ve
space - inside the transverse
stiffening tubes for the two
\
box-type frame fabrications.
Hence the motor capacity
for the accumulator feed
pumps is limited to the aver-
age demand of aU motions,
contrary to the direct elec-
trical single drive or the
hydraulic drive of one or
several cylinders by pumps.
Moreover, the working veloc-
ities are independent of
the instaUed pump capacity,
and the motions can easily
be stopped or reversed in-
stantly, without additional
components, thus increasing considerabIy the maneuverabiIity of the

manipulator.
The tongs are fianged to a holIow peel whieh rotates in a steel hous-
ing. The housing is supported in baII joints by four rodR ttnd conneeted
·Fig. 194. Traek-bollnd cleetrically Ojlerat!'d manipulalur for an ing"t m'igll! 01 J~ tons; ,110]1 pllo!o.
(lly: Demng, Duisburg.)
Fig. 195. S!top plloto of t!te fmgillg manipulator as ]ler fig. 19~ in cOlljunrt.irlll witl! a 2 ,200-1011
forging pres,.
to two pairs of front and re ar carrying lever arms to allow the carrier
frame to move in any direction. For lifting or tilting the tongs, each pair
of carrying lever arms are connected to carrying shafts which are mounted
in bearing pedestals on the frame boxes and which can be activated
:Fig, 196, 1,100·ton fo!'ging Pl'C"S with twa manipulatar"
lj'ig. 197. Tracl.. -hoHnd all-h;nlraulie model ()()·mt Illallipulator.

(By: Hydralllik, DlIislJurg,)
simultaneously or independently of each other. For special operations,

the front or both pairs of carrying lever arms may be provided with side
shift on the shafts to ena bIe a sluing position or a parallei shifting of the
tongs in the horizontal plain. The controls and the operator's seat arc
arranged lateraIly on the frame at a point where the tongs movements
can easily be observed.
/ ... ·_·_·_·--1
i i
! .
o
f]-o-
l!'ig. 198. Tl'uek-bound Rll-hydranlic n1a.nipulatoL (Ey: liydruu1ik, ])ublmrg.)
Table 25. Main Dimensions for Tmclc·bound All.hydmulic Manipu.latol"s

as per fig. 198
:Maximum load moment

W' Ţ
l
ft. /lbs.
I35,000 70,000 140,000 280,000 420,000 840,000
Ingot weight JV lbs. 5,500 11,000 22,000 44,000 66,000 132,000
Tongs
opening
} m.x. dl • .
m i • . dia .
in.
in .
I 18
7
20
8
24
Il
33
16
45
24
51
24
Tongs height
above floor in. 35 40 43 51 63 75
Track gauge
Drive capaci y
in.
H.P.
I
I
57
15
71
2 x l5
86 100 130 150
2x 28 2 x 28 2 x 40 2x70
]<'OIWING MANIPULATORS 239
Data for all-hydraulic manipulators may be noted from table 25. The
load moment is here determined by the distance of center of gravity of
the ingot to tongs center, contrary to the common manner where the
load moment is calculated in relation to the front axle to obtain the
tilting moment.
I,'ig. 109. Track·bounrl all-hyrlraulic morlcl120·mt manijlulator. (Courtesy: Soc. Temi, Temi, Italy.
Jly: Hyrlrau1ik, Duisburg.)
Vig. 200. S1I0jl pllOto of manipula tor n,; per fig. 190.
240 AUXILIARY MACIIINES FOR FORGING l'RESS INSTALLATIONS
Fig. 201 shows an oil-operated all-hydraulic manipula tor for a load

moment of 1 mt (3.6 ft.-tons), the tongs opening of which is 12 in.
max. Closing, lifting, and tilting of tongs are carried out by means of
working cylinders, while rotation of tongs and the travel motion of the
manipulator are performed by oiI motors, which are activated by pres-
sure oiI from an accumulator of about 1,100 psi., the rcgulation and
Oii Qccumv/olvr
,
""~
l'~~~~~~~~~.r"
Fig. 201. Oil-u('cumulator driven track-1)ouud manipulatar for a !oatlllHllllCllt of ImI, (:3.1l n.-toll').
(By: Hydraulik, Dub1Jnrg.)
revers al of tongs rotation being carried out by controling thc oiI supply.
The manipulator features extreme simplicity of its drives and can per-
form - due to accumulator operation - large and sensitively controllable
working velocities.
The use of manipulators in forge shops instead of cranes, parti-
cularly if series production ofaxles 01' shafts is concerned, resulted in
improved heat efficiency and considerable in crease in output. ln many
cases savings in time and costs up to as high as 75% have been obtaincd,
as compared with the conventional operation with cranc and rotary
chain. With the help of a track-bound all-hydraulic manipulator, C.g.,
a six-throw crank shaft, wcighing 7 tons, has been forged in fixed posi-
tions in three heats and a forging timc of 2.8 hours.
AUXILIARY TOOLS 241
Moreover, the physical work becomes less strenuous, thus personnel
and the demands to their skill can be reduced considerably.
d) Auxiliary Tools
Fig. 202 shows a steam-hydraulic 3,300-ton forging press with built-
in tools which may be suitably employed for forging wheels and turbine
disks. The ingot is put in center of a rotary table and bulged laterally by
means of two pressure plates which are mounted in a holding device on
Fig. 202. 3,300-ton forging l'fC, S with tool8 for forging wlleel. and turbine disk •.
(By: Davy lIrs. Ltd., Sllcffield.)
the crosshead and which can be positively moved apart or together,

transmitting the forge load centrally_ The table is actuated by a motor
through a bevel gear and a worm reducing gear. The motor runs conti-
nuously. Due to the arrangement of a friction clutch in the gear - simi-
lar to the electric rotary chains - care is taken that in case of sudden
stopping of the table when being hit by the pressure plates during forging,
an overloading of the drive is prevented.
16 MiiIler, Hydraulic }'orgillg Presscs
Crank turning machincs

are devices which work
independently of the forg-
ing presses; their purchase
is only profita bIe if crank-
shafts are continuously
manufactured. The turning
machine consists of a sta-
tionary pedestal with jaw-
~ shaped opcning and a turn-
able disk, both of which
I are mounted on a common

base frame. The disk is
driven either clectrically
by a gear or hydraulically
by a rack. The web of thc
crank to be twisted is put
into the disk and the
other web is held in the
pcdestal.
Hydraulic hoisting jacks
are used for various forg-
ing operations, but chiefly
for holding cutting knives,
notching knives, and com-
posing tools. The design
of a hoisting jack is iIlus-
trated in fig. 203. It con-
sists of a hydraulic cyl-
inder with a single-acting
ram which moves a pulley,
creating a rope pulling
force of 6 to Il tons. For
strokes exceeding 7 ft., a
larger ra tio is chosen and,
accordingly, more moving
pulleys.
Fig. 2()~. HydIanlie hoi~ting jack for

\vorklJiece8 aud tool:-i. (I~y: Hy<ll'aulil.;:,
DUh-ilmrg.)
CLOSED-DIE FORGlNG PRESSES 243
Chapter VII
CLOSED-DIE FORGING PRESSES

The demand for large quantities of shaped pieces of the same size,
made of forged steel, gave early rise to the idea that - in order to avoid
high cost for manual forging and subsequent machining - these parts
should be made from heated, crude or cogged blocks by counter-acting
of two dies - the upper and lower die - in only one single operation.
For carrying out this method every open-die forging press is suitable,
providing that an ejecting device exists for removing the drop forging
from the lower die. If the press, however, is to be used exclusively for
the manufacture of drop forgings, a cheaper design will do in most
cases, as the large stroke and the large center distances of the columns
as well as the daylight dimension for accomodating the tools are not
required. A closed-die forging press, therefore, may be distinguished
from an open-die forging press mainly by its sturdy and rugged design.
When making closed-die forgings out of steel, it soon became obvious
that the use of a press is only suitable if simple-shaped parts are concerned,
the shaping of which, however, requires a large amount of upsetting
work. For closed-die forgings, on the other hand, with relatively thin ribs
or rims requiring a large raise of the material, the press load is extra-
ordinarily high and the press usually is no longer economical. In this
case the application of a considerably cheaper drop forging hammer is
more suitable where the kinetic energy at the high impact speed of the
dies and at a short way of deformation is transformed into an almost
unlimited deformation force, thus bringing about a satisfactory raise
of the material. Hence the hammer causes chiefly a surface effect on the
drop forging, and the press a depth effect.
Closed-die forging presses for steel are particularly suitable for the
manufacture of wheel rims, center-web wheels, and solid wheels as per
fig. 204. They serve for upsetting and piercing the ingot while the final
shaping is performed on a rolling mill for annular shapes or a wheel-web
rolling mill. The use of hammers, stiH employed in older works, is out
of date; however, closed-die forging presses are readily applied in con-
junction with drop hammers, e. g., for making crankshafts. While the
closed-die forging press does the great amount of upsetting work when
cogging, the hammer is used for finishing only, that is for final shaping
with large power requirements. Cogging may also be performed on a
trimming press, the body design of which corresponds to a closed-die
forging press and which is equipped with two sets of tools. This tool
arrangement and the resulting eccentric effect of the press loads entail,
however, very unfavorable stressing of the press.
16*
244 CLOSED-DIE FORGING PllESSES
The superiority of the press - for carrying out upsetting operations -

over the hammer may best be explained by an example. If a relatively
large drop hammer has a potential energy of 20,000 mkg, this corre-
sponds to the free falI of a ram of 22,000 lbs. from a height of 6 1/1 ft.
It is known from general experi-
encc that this equals the working
capacity of a clm;ed-die forging
press of about 1,100 tons. When
cogging undcr the press, thereforc,
a press stroke of as small as
20,000 mkg 002 (3/ · )
S = 1:000,000 kg = . m 4 lll.
cquals the effeet of a full ram
blow from a height of 2 m (6 1/ 2 ft.).
Hence instead of one upsctting
strokc of, e.g., 8in., ten blows of
the ram would be required.
The capacity of a closed-dic
forging press is obtained as the
product of thc arca projectcd on
the horizontal plain and the rcsis-
tance of deformation which i8
known from cxperience. A stan-
dard of comparison of practically
.Fig. 204. lbilroarl solid wlil'l'b. applicd press loads for various
drop forgings i8 given in fig. 205.
In the rcccnt past closed-die forging presses have found a wide
application, particularly in the light metal industries. Leading in this
field were German light metal works which, as early as 20 years ago,
employed closed-die forging prcsses of capacities up to about 33,000 tons
for series production of aircraft parts, crankshaft housings, propelIcr
blades, etc. These presscs were dismantled after the war. Only about
10 years ago the construction of huge closed-die forging presses wa::;
commenccd in the U. S.A., with press loads up to 55,000 tons. The extra-
ordinarily high press loads are required for the manufacture of drop
forgings of light metal alIoys difficult to deform, which do not withstand
great velocities because of thc formation of cracks when they rise in thc
die and which, therefore, cannot be produced under hammers. The de-
formation by presses takcs place relatively slowly at a tcmperature of
about 932 oF with no ill cffects on thc high-temperaturc stability of the
die steels, despite the incrcased working period, as compared ta thc
deformation of steel at considcrably highcr temperaturcs.
CLOSED-DIE FORGING PRESSES 245
~I ~
I
~,-I~H- : ~~-- 1JOOt tt-@- ~

, I
275t
'-J; 111/2' ~ - - 19'
"F
- .9Y/- --'
~ ~ .., -
~
~
---- , -+-- ,
-! -,j~~
~ ._.
6W --- 5Yz" ,.. I ~ +

J •
i!i
crţc
, ~- I
,..- 1'1"- - ., l''/e'' r - ~: li
Ci;r==> ":20
'(w
'-- 1)%"- -
"'_
~
1.'
I,i
,
.-- '§G I ~
550t
@-
i%'-'
t
~ ( li H i
I
ţ~ co ~
~ :
Ir----$ ~ - li
- f}i/--
i!l- -P 6-
{0)-
LfW·...
_ "" 7'
#.~
">
1
I
~~ I-~
' . ~· "
,
@
J ,
~ -I-·-@+ ~- ~
r 1·
~
7-' • • I - 8' 1
, , 'foot
a_l'
• '1 ~.
-9f-i- I
b~
~
L-~- A ~
, ' I
~ 11· -., P
~-~O"-J ~?
}'jg. 205. Closed-dje forg jngs, produced under vadous prcsscs. (Vicws jn fiftit a ngle projection.)
246 CJ~OSED-DIE FORGING PRESSES
a) Closed-Die Forging Presses for the Deformation of Steel

Amongst the many hydraulic closed-die forging presses operating
in the steel industries, those presses used for making solid wheels, wheel
disks, and wheel rims are the most important ones. A complete instal-
lation for this manufacturing program is composed of furnaces, scale
breakers, and handling devices, a mill for rolIing circular shapes as welI
as a dishing press for cambering the whcel disks after rolling. RolIing
of the disks or rings is carried out after pressing operation 1 ). A wheel disk
is a hub body on which a whccl rim is shrunk while thc solid whcel is
made of one piece with rolled-on rim.
The sequence of press operations for making a wheel disk is illustrated
in fig. 206a to k. Two upper and lower tools each are used. They are
firmly connected to each other forming a set of tools and are mounted
on a carriage. Fig. a shows the extended upsetting dic with the ingot.
In fig. b it is brought into the press center and cent cred by tongs.
Fig. c shows the first upsetting operation, and fig. d the removal of
scale from the upset forging and the ring being lifted from the second
hole die. In fig. e the upsetting die with the ring is in press center again.
In fig. f the second upsetting operation is done and in fig. g the ring
with the forging is lifted from the die. Figs. hand i show the hole die in
press center and the pierced forging. In figs. j and k insertion of the
ingot is rcpeated and the forging is lifted from the hole die.
The forging if a wheel rim is illustrated in fig. 207 a to g. Figs. a and
b show how the ingot, inserted in the upsetting die, has becn brought
in press center with subsequent centering and upsetting. Fig. c illustrates
the completed upsetting operation after ~ as shown in fig. 206c ~ thc
die ring has been removed from the brought-in hole die and put on the
upsetting die. During the time which is required for removing the dic
ring from the hole dic, the scale is blown off the upset forging. Fig. d
shows the pre-piercing of the ingot for the wheel rim which necessitatcs
prior traveling in press center of the upper hole die and removing of thc
die ring from the upsetting die. Fig. e shows the lower hole die in prcss
center and insertion of a piercing disk by tongs, so that ~ as per fig. f ~
the upset ingot can be pierced. At the same time a new ingot is put on
the upsetting die which, in fig. g, is in press center again. The forging is
now removed from the hole die and brought to the rolIing miU.
The shaping of tools for the manufacture of solid wheels can be
noted from fig. 208. The carriage a for shifting the upper tool set moves
in a cast steel frame b with offset ends for mounting the shifting plungers
e, which are arranged side-by-side slightly ofI' center. The hole die
1) LEHMANN, O. R.: Radreifen, Radscheiben und Vollrăder, Dusseldorf: Vcr-

lug Stahleisen 1952.
CLOSED-DIE FORGING PRESSES FOR THE DEFORMATION OF STEEL 247
3
a g
~ .
I
.. I. . . •
e 1 . ' 1 k I I I
~
~=
» ~=
f
]'ig. 206a-k. Scquence of operation" when making a steel disk.

248 CLOSED-DIE FORGING PRESSES
c g
Fig. 20ia---g. Se-quellee ofOpf'l'atiOllR when rough-forging a wlwPl riUl.
consists of a stationary plate d with piercer e and a movablc die holdcr j,

which suspends from bolts g and which strips the upset disk upon retrac-
tion of the piercer by means of springs h. The beII cranks i of the tongs
are centered with the press and arranged on shafts j, which are turned
by levers k and connected to the movable cylinder block m through
linkage l. The plungers n and o do not move and arc fastened to frame b
by means of rods p and the crossbeam q. The forks rare pivoted in pins 8
and are held in the position shown by stop plates t. Thus they can only
i(l -
... _- . ~ .
-- - - . -11- 1-11>-...- ' _-';:"""~ "' _ __ - -----f-;-r +_ - _ . - --

be fiapped up and cannot deform when hitting the die after the die ring
has been inserted and the subsequent upsetting operation. The hole and
upsetting dies arranged on the lower slide table are simple cast steel
members with interchangeable upsetting disks, rings, and piercer
bushings.
The capacity of drop forging presses depends on the weight of the
ingots to be worked. For the manufacture of wheel rims usually an up-
setting load of about 2,750 tons is sufficient, while for solid wheels, e. g.
for field railways or trams, up to about 40 in. diameter a press load of
about 3,850 tons is required. Standard wheels for railroad cars are made
by closed-die forging presses with an upsetting capacity of 6,600 tons.
The largest existing closed-die forging presses are arranged for an up-
setting capacity of 9,900 tons, taking into aceount thc working of
alloyed steel ingots.
The design of the most frequently built closed-die forging press
-- a 6,600-tons closed-die forging press - is illustrated in figs. 209 and
210. It resembles a normal forging press and has a base platen, a moving
erosshead, and a top cylinder platen of cast steel with inserted press
cylinder. Base platen and cylinder platen are connected to each other
by four columns, using four split cast steel nuts on each. The base platen
rests on the foundation with four integrally-cast lateral brackets. A
hydraulic piercing device is arranged off-center underneath the cylinder
platen and on each side of the piercing cylinder a a return device for the
pier cer ram. Two hydraulically activated shifting tables on the base
platen and underneath the movable crosshead move on special wear
plates in a right angle to each other. Furthermore, a hydraulically
activated removing and transferring device b for the finished wheel disks
are arranged undeI' the cylinder platen. Above the base platen the four
columns are provided with split cast steel jackets for heat protection,
serving also as lower stroke limitation for the moving crosshead. The
main ram is rigidly connected to the moving crosshead.
At both sides of the base platen return cylinders care inserted, the
rams of which push against the moving crosshead from underneath
(see p. 63). Under the base platen - in press center as well as off centcr-
a hydraulic lifting device d for the wheel disks is provided.
The automatical filling device consists of two aiI' vessels laterally
arranged at the cylinder platen - the air vessels are under a pressure
of 85 to 115 psi. - and a filling valve arranged on top of the press cylin-
der. All idle strokes of the main press ram are carried out with low
pressure water from the air vessels, thus requiring pressure water only
for the very working strokes (see p. 148).
The press is connected to the power water station of 3,000 psi.
operating water pressure. A pressure intensifier, located above fioor
o
r
O
[fJ
t".l
Y
Ij
"""
t<:
':j
O
~
<:;")
iZ
"ti
"
~
t".l
[fJ
(fJ
~
':j
O
~
>-:l
ţ:q
t".l
Ij
t".l
>,j
O
~
s::
'>-:l"
2)
Z
o
':j
Ul
>-:l
t".l
t".l
r
t-:l
Cll
......
Fig. 209. Two·s(,age o,GOQ·ton one·cylillder dOBcrl·dic forging pr"" "ith off·center piercing dc\"ice. (By: Schlo(,IIlHnn, Dlisscldorf.)
adjacent to the press, produces the high pressure water of 5,700 psi.
(fig. 2lO). It has a cast steel cylinder - arranged at the bottom - with a
ram which is carried out as a high-pressure cylinder, and a top crosshead
with a high-pressure ram mounted to it. The cast stccl cylindcr is con-
nected - by means of two columns - to thc upper crosshead at which two
},ig.210. Sliop ]lhot.o of a c1o~ecl-(lie fOl'ging ]lfCSS fi S pcr fig. 2U9 with tHlj:wellt ]l)'('~~11T'(,; illtr ll !' iliPT.
lateral return rams are arranged, the movable re turn cylinders of which
pul! the low-pressure ram down (see p. 205).
AlI press motions are effected by electrically activated valve controls
which are push-button operated. The controls are safcly locatcd below
floor. The switch gears and the control pulpit are above floor in an
unobstructed location.
The one-cylinder design in conjunction with a pressure intensificr
- which increases the operating pressurc from 3,000 to 6,000 psi. -
offers the advantage that the press can work with tv.ro pressure stages
of 3,300 and 6,600 tons, thus decreasing the pressure watcr consumption
to half the amount during the working stroke when producing small solid
wheels. Moreover, the high operating pressure permits a sturdy and
relatively inexpensive construction.
CLOSED-DIE FORGINC PRESSES FOR THE DEFORMATION 0:1<' STEEL 253
The three-cylinder design (see p. 187) 1S preferably adapted for the

9,900-ton presses mentioned on p. 250. In this case, pressure stages of
l·'ig. 211. 1, IOO-ton one-('ylinder cl'owning preso with top aiI' vessd.
3,300, 6,600, and 9,900 tons may be attained although the pressure
intensifier is eliminated and the same cylinder dimensions are maintained,
and the power requirements can be largely adapted to the various
programs.
For dishing solid wheels and wheel rims a simple one-cylinder closed-
die press is employed. The press according to fig. 211 is designed for a
press load of 1,100 tons at 3,000 psi. operating pressure and has an
upper platen with integrally-cast cylinder. The air vessel with filling
vaJve is arranged directly above the cylinder bottom; this design is
suitable because of the small cylinder volume. The main ram is of chilled
cast iron. The return cylinders lie between the columns in the lower
platen. The die holders are firmly attached to both platens; the shifting
table has purposely been omitted with regard to simplicity.
Fig. 212 illustrates a closed-die press for a large and versatile range
of application, including burring of the drop forgings. Its capacity is
2,200 tons at an operating pressure of 4,500 psi. The lower platen as well
as the moving crosshead are - like the press shown in fig. 209 - equipped
with shifting tables , the directions of travel of which are perpendicular
to each other. While the lower table is operated by hydraulic rams, the
upper table is activated by electric motor through gear and pinion due
to little space requirements. This table arrangement permits multiple
dies to always work in press center, thus eliminating eccentrical forces
on the press frame.
Table 26. Main Dimensions for Trimming Presses
(according to DIN 9894)
rrcs.~ J .n• rgcst 'f'lIt<" r 11i st:lllC ( 'Olll l1l1l Ham diarnctcr
ap,\ci t y 'IT k c of t"lI (UIllII S- J)"rlighl difll11 l! ter d,
p /1 b tl L 'I t
Xomiu,,1 " ~
IIlinimuHl 1·\,500 Ils i.

O'
I
:1 .1~1l Il.L
'alJaclt y
tons in. in. in . ill. in. m. 111 . in.
550 17J / 4 55 36 44 10 22 17 J /4 631

700 193/ 4 55 36 44 il 25 193/~ 8
900 22 63 40 55 121/ 2 28 22 10
1,100 25 70 55 63 14 31'/~ 2.5 11
1,400 28 80 63 6:3 I Sa!.1 35 1/2 28 121/~
1,800 31 1/. 84 67 70 17 3/ 4 40 311/2 14
2,200 35 1/2 88 75 80 193/ 4 44 35 l / 2 163 / .
2,750 391/ 2 100 84 80 22 50 40 17 31.1
4,400" 44 132 88 88 44 35 1/2
5,500** 50 140 I 100 100 50 40
* Largest moment arm at eccentric
loading by press load P.
** These presses have two cylinders
arranged behind each other. d1 and
g to be adapted to requirements.
A push-rod serves for ejecting

the closed die forging. It is
guided in the lower platen and
connected to the moving cross-
head by a cross tie and two
lateral tie rods which are ac-
tivated by the moving crosshead
motion. The down motion of the
push-rod is completed if the tie
rod nuts, which are arranged above the lower platen, come to retlt. Upon
further travel of the moving crosshead the tie rods slide thl'ough th('
crosshead. This mechanical drive of the pUtlh-rod may also be replaced
by a hydraulic ram for very large pushing forccs l ).
The return cylinder is inserted into the bottom of the main cylindcr
which, therefore, is provided with a suita bIe opening for casting reasontl.
rrhe retUl'n ram is connected to the moving crosshead by a cross tic and
two lateral rods.
For trimming presses, the design of which is largely identical to tLat
of closed-die forging presses, standard dimensions have been established
which are listed in table 26.
b) Closed-Die Forging Presses for the Working of Ligbt Metals

The series production of aiI' planes entailed a high demand for engine
housings, engine carriers, fuselage parts, propellers etc. made of light
metal, which were me-forged foI' decreasing the weights and productioll
costs and which required - due to their increasing sizes - the instal-
lation of closed-die forging presses of extraordinarily high capacities.
Fig. 213 illustrates a closed-die forging press of three-cylinder design
for a press load of 11,000 tons which is also layed out for cogging and
planishing of, e.g., rings (sec fig. 5). For this reason, the stroke, the
daylight dimension between the shifting table and the moving crosshead,
and the column distances were ma de larger than would ha ve been re-
quired for only the closed-die operations. The detlign of the closed-die
press itl essentially identical to a forging pretls as per fig. 46. The arrangc-
ment of three identieal eylinders permits three pressure stages of }l
1: 2: 3 ratio. The relatively short stroke volume, as compared to a forging
press, permits smaller dimensions for the aiI' vessel; therefore, it ma,y bo
located abovc the cylinders with short conneeting pipes to the eylindertl,
thus assuring a high approaeh speed of the moving erosshead. The work-
ing rams are equipped with pressure rods in order to relieve the stuffing
boxes from eceentrieal forging resistances. The weight of the moving
crosshead as balanced by a constant pressure in two small cylinders
inserted into the upper platen.
The two return eylinders are arranged in the lower platen next to
two diagonally plaeed columns. In the cent el' of the lower platen lies an
ejecting ram whieh is pushed up - through a cross tie - by two lateral
lower pistons and moved down by small return rams located above. The
shifting table is extendable to the leU side and - in its end position -
1) MULLER, E.: Hydraulische Pressen und Druckflussigkcitsanlagen, Bd.2,
Pressen fUr die Herstellung und Verarbeitung von Rohren, Hohlkiirpcrn, Plattell
und Blechen aus Stahl, BerlinfG6ttingenfHcidelbcrg: Springer Hl55, S. 152.
CLOSED-DIE FORCING PRESSES FOn THB WORKING OF LIGHT :\lETAT,S 257
is placed with its middle bore above a second ejecting device , so that the
workpieces may also be ejected from the die outside the press. For this
device the ejecting stern is arranged on the bottom of the movable
ejecting cylinder which is forced back by two lateral pistons. The ejecting
I!S9fl
-- j
- - --r
, --
17 31iilIer, Hydrnnlic Forging Prt~~~{'"5

258 CLOSf:D-])m FORGIl\G PRESSES
ram is stationary and is eonneeted to the table bed - whieh is bolted

to the lower platen - through a eross tie and two lateral tic rods.
Details of the largest elosed-die forging press, whieh was built
during the past war for the German aircraft industry, may be noted from
figs. 214 and 215. At a closer look, two four-column pl'esses arranged next
to cach uther may be noted which are eonneeted by two common press
tables, namely the stationary lower table and the upper movable table
of about 33 ft. length and 10 it. width and about 8 ft. dayljght dimension.
The total press tonnage is 33,000 tons and staged in al: 2: 3 ratio. The
four working rams of each press are hollow-cast and seated on the ram
crossheads in spherieally machined plates. They ean earry out a stroke
of about 60 in. Above the cylinders four air vessels are arranged ,yhich
CLOSF.D-DIF. FORGING PHESSES FOR TIIE WORKING OF LIGHT l\IETALS 259
contain the low-pressure filling water. Both cylinder platens and the
press tables are carried out as multiple parts due to their large weights.
On the three-part lower table !ies a shifting plate which is extendable
towards the right preso; side. The hydrau!ic cylinders of the shifting
device are located below floor and are connected to the lower table at
each press side by two lateral tie rods. An ejecting device similar to the
one ShOWll at the press in fig. 213 is arranged in the guide bed for the
shifting plate. The shifting plate as well as the movable upper table are
equipped with interchangeable mounting plates. For the return of the
upper table, four rams are provided, the cylinders of which are arranged
in the lower platen of each press between the column jackets. The pressure
water is supplied through a center bore in the columns. The total height
17*
260 CLOSEI)-DIE FORGING PRESSBS
of the press is about 80 ft.; the headroom is 56 ft. and the depth bela,,"
floor 26 ft.
The following figures illustrate some of the largest elosed-die forging
presses whieh were built in the U. S.A. after the war in line with a defensp
program eomprising the manufaeture of closed-die forgings particularly
Fig. 2l5. Sltup photo of the ('jo,clhlie [orging 1>1""" us per fig. 2l-l.
for jet aircrafts. For this program the good experienees which had been
made in Germany as well as with a 18,000-ton closed-die forging press
which had already been operating in the U.S.A., were of great help.
Some workpieces produeed by this press are illustrated in fig. 216.
The basie design and the main dimensions of a 35,000-ton closed-die
forging press are shown in figs. 217 and 218 1 ). The design is similar to
the press illustrated in fig. 214. However, the press frame in which the
flux of force is established, does not consist of two eoupled four-colnmn
1) Iron Steel Engr., May Hlfii).
CLOSlm-DlE FOHGING l'RESSES FOR THE WORKTNG UF LIGHT :VIETALS 261
presses, but of four two-column presses arranged next to each other and
which are connected by through-tie rods. In each of the four top platcns
two equal working cylinders are arranged. The pressures are staged in a
1: 2: 3: 4 ratio, in the first and third stages either the two inner OI' outer
cylinders are diagonally activated. The working rams are equipped with
r---- - - -1'{1S- -=---=-- ,..,
J'eclion A-A
j;·ig. 21G. T,jght metal clo~ed-(\ie forgillg", 1'1'O(]uecL1 by a 18,OOO-tOll c!osc!l-die forging jlI'''''.
pressure rods - as shown on the press in fig. 213 - in order to prevent

distortions of the stuffing boxes by eccentric press loads. Special ram
crossheads like on the presG in fig. 214 are not provided, however, the four
moving crossheads are fitted with a two-piece table plate for mounting
the dies. The built-up lower platen - bolted together by tie rods -
is providcd with a unilaterally extendable shifting table of 24 ft. length
and 12 ft. width. At the head emis of the lower platen four re turn
cylinders are arranged, the rams of which transmit the load directly
to the moving crosshead. For ejec:ting the workpieces from the dic, thrcc
ejecting cylinclers with an effec:tive ejecting force of about 770 tons arc
loc:ated in the lower platen. Thc: lower platen rests on two supports
anchored to the foundation. The pressure and filling water is :mpplied
to the cylinders through bore8 in the columns, which have an outsidc
diameter of 34 in. The filling valves are arranged below fioor, as the idlc
and working speeds are relativcly low and only smaII pipe and valve
fiow areas are required. Thc pressure water station consists of a com-
pressed-air loaded accumlllator and fivc vertical five-piston pumps for
a combined ontput of abont :3,500 II. P. at an operating water prpssUIT'

of 4,.'500 psi.
Fig. 219a anei bare shop photos of a closeei-clip forging press \Vit,h a
capacity of about 50,000 tons. It. con::;ists of - like the pres,; in fig. 214 -
~---------- otfjst------~--- flgZt ----'

CLOSED-DlE FORGING PRESSES FOR THE WORKING OF I,IGHT .\'lE'l'ALS 263
two four-column presses connected together with four working cylinders

each, which are, however, not arranged in pairs placed side by side but
on one common axis. The outside diameter of the columns is 40 in.
Apart from this the press design shows no considerable difference as
Fig. 21". 1-iho[l photo of thl' 010,('<1-IIi" !i)rging preso ",; ]ler fig. 21 i.
compared to the afore-described press. The length of the press table

i8 26 ft., the width 12 ft. and the daylight dimension 15 ft. The rams
can perform a maximum stroke of about 70 in. The determination of the
pre8sure water consumption has been based on 30 strokes per hour of
12 in. length.
The manufacture of the lower and upper platens and the moving
crossheads of the two afore-described heavy drop forging presses makc
great demands upon foundries and machine shops. Each platen consish;
of individual parts, the dimensions of which are limited by their large
weights, which cannot be exceeded further and which - when assembled
- cannot be machined nor handled. The same holds true for the columns
which have ta be farged from the largest ingots weighing about 275 to
330 tons. These difficulties entail also uncertain factors in the calculation,
particularly with regard ta stresses in the calumns, as the construction
264 CT~OSED-DIE FORGl~U PRESSES
CLOSED-DTE FORGING PRESSES FOH THE WOltKING OF LIGHT METALS 265
J<'ig. 220. ;;5,()()O-ton cloReei-dic forging lIrc" with six cylindcrs aud four lamillatcd eoluulIls 1 ).
Fig. 221. COllllllOll mHehining ofthc laminatioll:-:i OfOllf' tie rod l ).
1) Figs. 220 to 224 by l;ourtcRY of BLH's Industrial Equipment Division

(formerly Loewy-Hydroprcss).
266 CLOSEIJ-DIE [<'ORGING l'HESSr;S
components callnot be assembled

without clearance - aue to un-
avoidable machinillg inaccuracies
- and as their eonnections are
subjected to the various degrees
of heat.
These com,iderat.Îons led to il
new way of shaping important
construction components for the
c1osed-die forging presses - illus-
trated in figs. 220 and 223 -
which are designed for the same
loads and table dimensiom; as
thc eolumn presses in figH. 217
and 219. They feature platem;
made of one-piece rolled plates.
the bcaring surfaces of whieh
can be machined when the plates
are put together, and - insteao
of round columlls - tie rods of
forged plates with hammcr heads
(fig. 221) which transmit the loar!R
through spherically maehilled
seats evenly to the erossheads.
The suitable shape of the hammer
head has been established by
thorough investigations on mod-
els (see fig. 222).
Another feature of thesc
prcsses is the fact that the under-
floor drive has been chosen (see
p. 12) in order to decreasc
the frequently arising vibrations
upon decompression, the center
of gravity of the press being con-
siderably lower than on presses
with top working cylinder.
Vig. 222. Photoelastie te:-;t~ at spyera] hallllllcr

he:ul :-;hal)t'~ for lamillah'd tiI' ('()(h;l).
1) See footnote on p. 2()i).

CLOSED-DIE FORGING PRESS~;S FOR THE WORKING OF LlGHT METALS 267
Fig. 2:2:_{, 50,OOO-tOB do~('d

uit' forging press with ni ne
eylil\(lrfS aud ~ix tie 1'0<1:-;1).
Fi~. 22~. Model of the ;;0,000-1011 do,,·d-dit

forging lJl'l'~::-; as 1)('[' fig. 22:{').
1) See footnote on p. 265.

268 CLOSED-DIE FORGlNG PRESSES
'fhe 35,OOO-ton closed-die forging prcss as per fig. 220 has four tic
rods which slide in long guides at the stationary working table. Eueh
pair of tie rods is moved down by three rams acting on a eros::;head.
Hence, in the lower supporting crossheads for the plate::; a total of six
eylindcrs are arranged, which permit six prcssure stagcs in conjunctioll
with a pressure intensifier, by cither activating t,nL {our. OI" "ix ram".
~ slulioflOry paris
D moving paris
J'ig.225. ·chl'matic draw ill$! of:1 projecte·"
Eil{;\ji~l Pres.su~ woler 75,OOO-to n f"l o>c(h li o fo rginjl prc"s.
The 50,OOO-ton press as per fig. 22:3 has six tic rods and nine eyliJl([er:-;.
a180 permitting six pres8ure stageo; where either three, six, Oi" nirlP
eylindcrs are activated, either direetly or in eonjundioll with the inten-
sifier. Four re turn eylinders are arranged at the stationary ,nll"i,ing
table for moving the frarne upwards.
\Vith rcgard to an antieipated further inerease in clotied-die forging
dimensions, a 75,000-ton presti has already becn designed, but hat-! not
yet been earried out. The basie design of this pres,.; - which is similar
to that of the largest column presses - may be noted from fig. 225.
LOCATION AND MANUFACTUREH OF LAHGE FORGING PRESSES 269
Location and M anufacturer of Large POTging Presses 1 ) (Status as of 196:2)
c..:·IJ);lt-
LocaliOIl (t'on,p:1I1)") ih-
(toi,,,)
Gl'eat Bl'itain
En al. •' teel - orp_
Ltd" Sheftield 7 _iOO _-\rm 't r'ong 191:l Fo rmerl\, steam
p urn ps, converted H)34
in to dire 't le 't ri c
\\-111_ Bea,rdmorc &. pllrnp ell'ive
Co .. Gla, (fO\\, O.GOO DlIlIcu n Ste\\'art. nc\\' T\\'o.cy linder pres.
pa l't Il,' - Da,-." and .. tcam int cnsiticr
lJnitcd Eng, o, lfJ34
Thos, Firth & John
Bl'o\\'n, Sh ffield 6,600 Da ",' - Brothcl'S IlH I T\\'o- c,dineler pres .. ,
stcam intcnsiticl'
Fr'a n ce
:'[a rrel F rCre '.
E i\' de Gie[' 6.600 I3rcllcr- Formerly stea m inten-
Sth u lI lilther 190G iti r, convcrtcd Înt o
electri c spindle inte n -
hat ill on-Commen - iticl'
tr,' -' Mont l u ~o n (UiOO Haniel &. Luc(t 1921 T hree-stage pl' " ,
pllmp .. , co mpl'essed-
aiI' a ccu mulator'
Acierie, el la l\Iarine. (;.GOO V ry olel prcss.
St, ha mont , team intensitier
.-\ei(·rie,: ele Firm ill\-.
l~irl1lin'y ' 6,GOO H ol'll1<' & Bll ire 1941 Fit am intens itier
Usi nes 'chneicl 'r'
L e reu ot fi.noo H."elril lI lik 1952 Thrce-cylineler pl'ess ,
corn pressed-a.ir' a('Cl\ -
)\ c th e rl an d , mulator
Hotterelam Dock,-ard
o .. Hottcl'c1arl\ Ci,GOD Loc,,'.'"_ Englancl T lll'ce- y linder' pr'ess,
com pre ','ed aiI' accu-
mulato!'
Ge rm an \"
1\ rllPP: Esscn 5,500 Da,-,' - Brothcrs 1908 T ,,-o-cylineler p rc.....
stea m intensiti 'l'
Kt'llPP, E sen 16,500 K l' lIPP 1928 Three-cy linder prcss,
team inten itiel'
Krllpp, Essen 5.:::;00 KrllPP 194 1 Two-cylinder pre, s.
stcam in tensitier
DOl't llluncl- Horcle "~::: I G,500 J(I'ClI SC' I' - Wagnc r l!)32 Two- cy li neler pl"ess.
pUll1p", compre' el-aiI'
"' ,
Guteho lfnulI<YS- ,~
hiitte. Diis' '1 lod"
I 5,GOO I:;ch loel11,) nn
ac 'ullluintor
Thr'ee-c,, 'li ndel' pl' , --.
co ml "css d-a il" a 'cu-
mula to r:
,' tah l\\' l'k
B nlLlIl, ch \\'eig 5,600 , 'ch loellla nil Threc-cy lind l' pr'c, "
compe .. , cd-a ir: a cu -
mu lato!'
1) J,lron St,eel Instit, Febr, 49 (supplementecl),
270 LOCATIO~ AND MA~UFACTUHEH OF LARGE FORGl:\G l'RESSES
Location and ]);[anufacturer of Large Forging PreSSfS

(continued)
!.<le" ti OIl ( '01111':\11)") )la ulI fa elu rrr aud ~'C4lr
Rulu'stahl A
Hattingen 6,600 Hydraulik 1947 Three-cyl inder press
compressed.air ac u-
mulator
Georgsmarienwel'ke,
Osnabriick 8,000 Hydraulik 1955 T hl'ce.cylinder pre ,
compre ed-air accu·
C ze c ho lovak ia mula.tor
\\' itkowitz, Bergbau
u, Eisenhiitten 5,000 Davy Bl'other Two- cylinder press,
, team intensifier
\\ i kowitz, Bergbau
u. Eisenhiitten 6,600 Davy Brothm Two·cylinder press.
team in tensifier
, kodawerk 5,500 Da"y Brother
Italy
T erni Soc. per l' In-
du tria., Terni 5,000 Davy Brother. 1910 Two·cy linder pre ,
direct pump drive
Temi, oc. p er l' I n-
du tria , T emi 13,200 Davy Bmt h rs 1934 Three cy linder pre .,
I
direct pump dri,-e
'ocieta Italiana
Acciaierie, Genova 8,800 Hydmulik 1938 FOrmerlY steu m-
hydra.ulic, Dav.,· one-
, 'ocieta Italiana "linder converted
• ccia.ierie, , enova 5,500 Hydraulik 1938 it;to compressed-ail'
I accumulatorand pump
Sov iet -Union
I
Barl'acada-V\ "
Sta Iingmd 6,600 Dav)" Brother's 1914 'uppleJllented in 1932,
two·cylinder press,
tea m intensifier
Kramatorsky
)Iachine Works,
Kramatorsky 16,500 ,chloemann 19!:l5 1Three-cylinder pre s
wi th guide stalk,
stealn intensifier
Krama.tor k y
:'oiachine Works,
Kl'amatorsky 11 ,000 Hydraulik 19a4 Three.cylinder pre s,
steum intensifiel'
Ura l Machine Work;; 11 ,000 Hydrau1ik 1934 Three.cylinder press
tealll intens ifier
U ral Machine \Yorks 6,600 H ydraulik 1934 Three-cylindel' pre s,
'team in tensifier
Putilow ,~ orks,
Leningrad 13,200 Davy and U ni ted- Two-cy Iinder pr s',
Eng. 1939 four intensifier for fu·
t ure modification to
fly wheel syste m with
electri c pumps
LOCATlON AND MANUFA CTURER OF LAItGE FORGING PItESSES 271
Locution and M unufacturer of LUl'ge Forging PTesses
(continued)
l"ap",'·
I.cx:a ti ull I l 'OIII!'all)") it\' Ht'l lIitrk'"
(I e!l',,,)
Japan
Japa,nese ' 0\' I'n·
lllent 6,600 Da vy Brothc rs 19 \(i T\\'o·cyl inder prcss.
:tealll intensifie r
J apanese c.o" el'l1·
ment 13,200 U nited EnO'. & Three· 'y lind r p1' ,
Founelrj' Co. 19H8 plllllp:, compresseel.air
a .' 1I III li la or
~avy Orclonan e
O,a ka Hydra ulik HJ38 Thl'ee.cyl ind el' pre ,
pu mps. o· mp.' .'eel ·air
I .5,500
accull1ul ator
, 'eik o 'cho Kob Hydl'aulik 19:3H Three.cylinder pre ,
pUl1lpS, compress d·a ir
ac 'ulllll lator
'eikoscho l\Iurora n 1 1,000 H y drall li k 19:37 T hree-cy lind er pre s,
pllll1pS . compr ss cI·air
a ullllll ator
:Xav\' Ordonan c
Ki'Ire 1(;,:-;0 Hydralllik 1935 Thl'ee.c,v linder pr. . s.
(dislI1antleel) pump , compre. sed·a il'
ti CCllmll la tor
Cni te d ,'tate,' of
.Am e ri c a
Beth lehe m S te el 1::>400 Bct hl chc m 1893 Two- cy lind er pl' SS,
11 0 O'uide stalk ,
steam p llll1pS
a m cgie , 'tel'l ,
Illinois 13,200 Beth Ichcm J!JOO T\\'o-cy lindel' pre. :,
no (TlIide talk.
stea m pump
:\1idva le, teel 8,300 l\iidya le 1904 One·cy lind l' pl'ess.
stea m pllmps. pl li 11 O'e l'
I'i a iclly co nnecteel to
. ,. :X avy, har- mov in ..' cros head
le. t on 15.400 :Uesta :\Iach. 19 19 Thr ·ey Iind er p1'ess,
inclined support · from
ba e pla.te'l1 to top
cro:sbead , s tea m in-
t ensifie r
:\Jieh'a le , ee
tI 7.200 Un ited En g. 1920 T\\'o-c,l'iindel' pres~
guide ta lk stea m
pump.
Bet h cI hem , 't el ,250 l\[esta, :\Iul'h. l!J40 TII'o·cvlineler pres'
no gulde ta lk. st~1Il
in tensifi l'
l;. , '. 1\avy. S.· 'har·
le, ton 7,200 U nit cd E11O' . & TII·o.c,Yli ncl er pl-ess,
FOllnch'~' 'o. .I!J44 g uide :stalk, pllll1pS
comprel ed·ail' a 'cu '
mul a O I'
272 T,()CATJON Al\"D MAJ\TFACTGHER OF LAECE FORGINC: PRESSES
Locatioll and jl'1l1l/llfacturrr of 1~l!rrJP FOl"yinq Prp8Sf8

(continued)
I .n<:ntioll ( l · UlHPn ll~ · )
L' .•'. );a \' \". • '.- har-

leston ' [:),400 )lcsta Ma ·h. 1944 Thl·cc,c.\·lincle r pres;;.
in 'Iined SU PPOl'ts hom
base plat n to t op
ero head, ce n t rifuga I
pump ·. cOlllprc eel· air
aCClIlllll la tor
'al'ncgic , 't 1,
Illinois I 7,700 .\f sta )lu ·h. 1944 TII'o- ·.dind r pl'C~S ,
110 O'uide stall<,
eent rifllgal pump. .
com prc~s el-a iI' kl CClI -
Illulator
. , ' . :\a\·\' . . '·Clull'-
.
le ton . 15,400 Un itcd Eng. (. T\\'o-cy lindel' pre 'S .
FOHndr.,' o. 1!J44 guide stalk o[ lle\\'
ele ign, pump. eom -
pres~ed .air acclIlIl ula-
tOl'
Midnll e ,' t ee l 15,400 IJniterl Eng. & T\\'o- y linel l' pre s .
Foundr.,· o. 194i'i guide talli: of ne \\'
elesig n. t\\'o . tcam
in tens ifiers
i\lcsta )[ac h. Co. a.GOO ~rc ta Mach. 194;) T\\'o-c.dinde r pre ,',
no g llidc sta lk ,
n t rifllga l PUIlIP, ,
co m pre sed-a iI'
aceumu la tor
INDEX
Absorption, 8, 38, 124, 131 Base platen, 12, 15

Accessibility of column press, Il, 63 Break-through of ram, 64
- of controls, 167 Breathing of press frame, 74, 7G, 224
- of single-frame press, 13, 72 Buttress thread, 34, 35
Accumulator, auxiliary devices for, 123
bottles, Il 7, 119 Calculation, examples of, 197
controls, 116, 124, 126, 127, 128 Cam drive, lG5, 171, 175
drive, 9, 10, 115, 120, 122, 146, Ca sting stresses, l()
175, 187, 216, 235, 240 Central feed, 10, 146, 217
-, floatless, 116 Centrifugal pumps, 77, 123, 219
- for oii, 8, 120, 240 Chain screen, 27, 34
-, installation of, 130 Charts, see list of tables
- operations, 124 Check valve, 136, 161, 177, 183, 184,
-, weight-, 115, 216 187
Accumulators, 114, Il5 Clearance between columns, Il, 14
Advance ram, 212 Closed-die forging presses, 13, 243
Aging of oii and water, 7, 132, 138 - - - - - for light metals, 25G
Air bottle, 117, 118, 119, 120 - - - - - for steel, 24G
Air cushion, 53 - -- forgings, 244, 245, 261
Air-hydraulic forging presses, 8, 63, Coefficientofefficiency, 2, Il, 77, 100,
66, 9~ 152, 170, 17~ 211 107, 121, 139, 172, 219
Air pressure, 10, 100, 131, 155 - - resistance, 140, 142, 156, 164
Air return cylinders, 65, 179 Cogging, 121, 123, 149, 156
Air vessel, 131, 133 Column breaks, 29, 72
- -, auxiliary, 132, 190 deflection, 31
- - gauges, 134 diameters, 30, 33
- - on top of cylinder crosshead, 53, feet, 17,37
154,258 guiding of moving crosshead, 2(i,
- - pressure, 63, 131, 153 30,56,59
- -, pump-suction, 88 load cases, 28
- - volume, 131 lugs, 17,25,37,38,56
- -, wall thickness of, 132 pre-tension, 3G, 38, G9
- - with oii operation, 132 press, Il, 13, 15, 108
Automatic motion, 183,224 sleeves, 35, 69
Auxiliary air vessel, 132, 190 stress,26
Auxiliary devices for accumulators, Columns, 26, 30
123 -, laminated, 266
Average demand, Il, 121 -, off-set, G7
Axial piston pump, see pumps -, rectangular, 26G
-, square, 35
Bach's formulas, 39 Comparison between kinds of drive,
Balancing cylinder, 57, 65, 66, 190 9,211
18 l\Iiiller, Hydraulic Forging Presscs
274 INDEX
Comparison stress, 40, 44 Deformation resistance ai piercing, 4

~ ~, graphical determination of, 41 - ~ at upsetting, 4
42 Delivery, see pump delivery
Compressed aiI' accumulators, 117 diagram, 9, 80, 82
Compressed aiI' operation, 21, 6:3, of existing drives, 69, 89
155,215,216 -- of feed pumps, Il, 121, ]22
Compressibility, 6, 8, 76 with direct drive, 76
Compressor for compressed aiI', 130 Depth of press below /ioor, 12, ()(;
Constant return when planishing, Design examples, 195
149, 157, 170, 179, 190 Destruction of concrete, Ref' fOUIl-
~ ~ with auxiliary devices, 148 dation
~ - with presses with crank gear Diagnostics, 192
intensifier, 108, 183 Diagrams for 8" 40, 41
- - with steam operation, 187 Die, 5, fi, 14, 20, 24, 5G, 71i
Control gear for accumulator, 116, 12a - plate, 5(), G9
-- - ~ ~ operations, 152, 175, 17G, 177, ~ shifting device, 11, 2:{, 1\7. 148
18a, 186, 187, 189 - shifting load, 22
-- ~ for ejector, 148, 167, 18G -, width-length ratio, 5, 14, 1:';. 7(;
~ - for table shift, 148, un, 18G Direct drivc, 9, 7G, 91, 123. 182, J!)O
-- gears, 148 Discharging pressurc, 157, 174
-- -, automatic, lG8 Distribution blocks. 144
Control positions, 149, lG7 Diverting linkage, G9
Control valves, 148, 150, 158, lG4 Drain screws, 53, 54, ] 58
- - calculation, 164 Drive, direct, sec direet drive
- -- drive, 160, lG5, lG7 Drive, indirect, sec accullluiator drin'
- ~ for load stages, 148, 17G Drop of rotation, 10, 108. 12:{
~ ~ for planishing, 157 Dry-running, 49, 91
~ - for pressure stages, 148, 17 ii, 177
- -, relieved, 158, lGl, 163 Eccentric forging load, 1:"), 2fi, 5(;, (jO,
Cooler, laf), 138 61, GG, 72, 74, 243
Corrosion, 7, :{5, 120 Economy of accumulator operatioll,
Cover plates, 19 21G
Cranes, ~ee forge cranes of compressed-air operation, 21;').
Crank gear intensifier, see intensifier 2Hi
Crank turning machines, 242 of direct pump opcratioll, 220
Crowning press, 25:{ of drive, 10, 22:~
Cylinder bolts, 47 of presses with mechanieal inkn-
- bottom, 45, 53 sifier, 22a
- calculation, :{9 of steam-hydraulie forging preSH.
-, closed, a9, 41 211
- inside diameter, 39 of steam operat ion, 212, 2Hi
- liner, 47 Ejecting deviee, 14,24. ()5. 148. 187,
-, open, 41 243
~ dimensions, 22
platens, 25, :')3
- sealing, 48 - force,22
- shoulder, 46 Elevated tank (see aLso reservoir).
132, 148
-, smallest outside diameter of, 41, 4:3
~ wall thickness, 39
EmuIsion, 7, 137
Energy consumption, 9, 99, 22:~
Cylinders, 38, 53, 75
Equation of state of eonditions for
Daylight, 14, 15 high pressure, Il 7
De/iection of top platen, :31 Equation of state of conditions for
Deformation resistanel', 4 low pressure, 132
INDEX 275
Examples of forging outpout, 91, 170, Hollow columns, 33, 259, 261
217, 223, 240 Hollow ram, 55, 61, 258
Expansion of vessels and piping, 6, 77 Hydraulic circuit diagram, 150
Exponent n, 117 - - - for accumulator operation, 152,
175, 177, 183, 186, 189
Feed pumps, 10, 114, 120
- - - for auxiliary devices, 186
Filter, 7, 136, 139
- - - for presses with mechanical
Fire hazard, 7, 66, 223
intensifier, 183, 184
Flange calculation, 47, 52
- - - for pump operation, 182, 18:3,
Flanges for high pressure, 143, 144,
14,", 185, 191
Hydraulic speed, see flow velocity
Flanges for low pressure, 146
Flow area, 1, 7 Ilgner-unit, 114, 184,223
- - in piping, 1,3, 7, 140,217 Indicating of forging presses, 192
- - in valves, 3, 7, 86, 151, 156, Hi2, Indirect drive, see accumulator drive
172, 187 Ingot, 2, 3
- resistance, 7, 63, 136, 140, 156, 164 In-line pump, see pump
- velocity in piping, 86, 140 Intensifier, air, 8, 10,99, 180
- - in valves, 86, 152, 156, 164, 172 -, crank gear, 9, 10, 107, 108, 109,
Flywheel, 10, 108, 123, 217, 221 183, 222
- calculation, 108 - - -, drive capacity of. 107, 108
- moment, 10, 108, 113 -, horizontal, 110
Forge cranes, 224 -, main dimensions of, 101
Forging, eccentric, resistance, see -, mechanical, 107, 183, 223
eccentric forging load -, rack, 112, 223
hammer, 1, 224, 243, 244 -, spindle, 114, 184, 223
of barrels, 13, 19, 56, 58 -, stage, 105
output (see also examples) -, steam, 8, 9, 99, 181
ratio, 2, 3 Jntermediate air vessel, 132, 190
temperature, 4, 244
Foundation, destruction of, 7, 22:3 Kinematic viscosity, 140
-, loads on, 1, 12, 66 Kinetic energy, 6n, 115, 243
- platen, 12, 15
Laminated columns, 266
Four-column design, 11, 14,28
Laminated crosshead, 266
- - - -, main dimensions, 15, 22, :n
Leak oii, 7, 66, 138
Four-valve control, 149
Leak water, 8
Four-way valve control, 151
Lip packings, 48, 50
Friction resistance of packings, 7, 48
List of tab les, 279
Gaskets for pipe connections, 145 Load cycle, 32
Gland ring flange, 49 Location of forging presses, 269
nrippers, 224, 230 Lowering speed of main ram, 1.56, 192
Cuide stalk, 32, 72 - - with compressed-air accnmu-
lator,117
Hammer, see forging hammer - - with weight accnmulator, 116, lHi
Heat elongation of crosshead, 27, 54, 1
58,66,69 r' ratio of, 80, 84
Heat radiation, 27, 33, 63 Lubrication, 7, 49, 61
Height of press, 12, 32, 66, 106, 115,
133, 219 Main control, 148, 152
High-pressure shutoff valves, 144 Main control, supplemented, 157
High-speed forging control gear, 168, Main dimensions, see tab les
171 Manipnlators, 224, 231
Hoisting jack, 242 -, mobile, 232, 234
18*
276 IN1H~X
Manipulator8, oii operated, 234, 240 Overall dimensions, sec tablcs

--, track-bound, 232, 234, 238 Overflow valve, 131, 13(l
Manographs, 192
Manual control, I61l Packings, 48, 150
Manual force, 166, 171 - for pumps, 815
Mercury control unit, 124, 127 - for steam- and aiI' intensifier, 102
Mode of operat ion of accuJllulator Penetmtion dcpth, 107, 114, 121, 122,
control, 124 179
Mounting plate, 156, 118 Picrcing device, 250
Moving crosshead, see moving frame Pilot control, 148, Hifi
- - design, 13 - - val ve, 161, lfi6, 171
-- - guide, 14, 26, 32, 15(l - oii prcssure, W8
- frame, 12 Pipe diameters, see flow area in piping
-- - design (see al80 presscs), Il, 30, Piping, 140, Hl4, lfi7
32, (l3, 66, 222 Piston pump (see also pumps), 78
-- weights, 12, 63, 66, 170 - ring, 7, 152, fii>
~Iultiple-cylinder presses, 25, 54, 149
- valvc, 7, 141, 1151, 174
---piece platens, 17,61,259 Planishing, 149, 157, Hi8
-- -piston pumps, see pumps - control, 157
Platen connections, 35, 3fi
Neutral position, 190 Platens, multiple-part, 17, (lI, 215fl
Diitrogen, 8, 120 Point of ignition of hydraulic; oils, Il
Xominal press load, 38 Prefill val ve, 1152, 1.'>8, 1515
Non-uniformity, 80, 81, 82, 83 - - designs, 1.'i4
Number of strokes, 1, 12, 107, 110, - - flow area, HiG
1157, 170, 18~ 192,224 Pre-opcning valvc, 1154
- - - of existing presses, 69, 108, Press eapaeity, 1, 38
110, 114, 122, 157, 180 - - boundary valucs for different
-- - -, reading of, 192 designs, 13, 14, 17, 00, 65, 72, 16(j,
Nut loeking, 35 212,244
-- tightening, 48 - -, determining of, 2, 244, 2Mi, 250
Nuts, 35, 38 - - of large presses, 24:3, 269
Press cylinder, :38, 5:3, 75
OiI accumulator, 120 Prcsses (illustratcd and described
- cool ing, 138 presses)
-- operation, 6, 66 -, oil-operated, fi8, 70, 71
-- -, coefficient of friction, 141 -,open frame (see a180 single {ranle
-- - for manipulators, 234, 240 pre8ses), 73, 75, 109, 222
-- -, gland ring for, 49 -, pulldown, fl7, !i8, 70, 71, 2(l5, 2fi7,
- operated presses (see also presses), 2fi8
(l(l, 70,72 -, three-eylinder, 1:3, 23, 27, 57, ;iB,
pumps, 77, 81, 91, 222 (l8, 188, 189, 219, 257
qualities, (l -, two-eolulllll, 67, G8
reservoir, 137 -, two-cylinder, (l0, 70, 71
- shutoff val ve, 13(l with power stages, 188, 189, 2l!J,
One-cylinder press, 59, 212, 219 2fi7, 258, 2fi2, 2fi4, 2(j;\ 2fi7
Operat ing pressure, 10, 38, f)l, (i3, with pressurc stages, 58, 252
99, 115, 122, 218, 235 with table shift, 23, 60, G7, (18, 70,
- - of existing presses, 70, 715, 89, 71,75, 188, 189, 191, 2iil, 254, 257,
108, 114, 130, 187, 190,250,262 258, 262, 2G4, 2!i7
Operations of accumulator control, with tool shift, 23, G8, 188, 189
124 Pressure drop, 140, 15(l, lG4
Outside diameter, smallest, 40, 45 - fluid, (i
INDEX 277
Pressure intensifier, 65, 149, 176, 219, Relief valve for control val ve, li)9,
250 161, 162
loss, 7, 124, 136 Remote control, 167
oii pumps, 91 - drive, 167, 170
rod, 15:3, 155, 61, 69, 261 Return, constant, see constant return
stages (see presses) - cylinder, 37, 63, 108
test for ac cumulator, Il8 - -, central, 69
- - for air vessel, 133 - device, 14, 63, 148, 218
- water amount, 120 - - for steam operation, 65, 178, 187
- - pumps, 78 - load, 63, 66
Prismatic guide, 35, 61, 26;3 - speed, 63, 157, 172, 192
Puller screws, 49 Reservoir (see also elevated tank), 88,
Pump, axial piston, 96 132, 135, 137
- capacity for accumulator opera- Reynold's number, 140
tion, 10, 120, 235 Ring mains, 143
- - for direct drive, 9, 71;, 77, 79, 234 Rocker shaft, 158, 165, 166
components, 82
data, 91 Sequence of operations with closed·die
delivery, 9, 8:~ forging, 246, 247
Service life of packing, 7, 49, 85, 219
drive capacity, 91, 122, 123
-, in.line, 70, 93 Servo controls, 149
-, multiple piston, 80, 81, 83, 91 Servomotor for control gcars, 166,
of five.piston series design, 70, 93, 169, 187, 190
261 - for variable delivery pumps, 98
piston load, 89 Shifting band, 22
-, radial piston, 91, 92, 93, 94, !lii dimensions, 22
- speed, 89, 91 drive, 21, 22, 69
-, standard dimensions, 87 force,22
-, triplex, 79, 80, 81, 89 stroke, 19
- valves, 8.'; table (see also presscs), Il, 14, }fI,
Pumps, 9, 76, 120, 220 148, 186
Push rod, 1154. 15ii Shipping weight, 17
- - control, Ulii, lt37 Shock absorbers, Il5, 217
- - force, 1:35 Shrink bolts, 17, 75
Shutoff valve, 148
Radial piston pump, see pumps Shutter, 135, 148
Ram diameter, 39 Single frame presses (see also open
- friction, 48, 4H frame presses), 12, 72, 76
- sealing for oii, 7, 48, 49, 91 - - -, main dimensions, 7!i
- - for steam, 65 - stroke, 10, 98, 100, 104
- - for water, 7, 48, 219 - -, progressive, 10, 98, 180
- velocity, 1, H, 172 Smallest outside diameter, 44, 4;)
- -, control of, 78, 162 Soft packings, 48
- - for pumps, 84, 91 Solid wheels, 243, 24!i, 2t32
- - for steam intensifier, 100 Solubility of gases, 8
- -, reading of, lH2 Space requirement, 77, 78, 217,
Keciprocating strokc in the accumu· 222
lator, 120, 126 Space requirement of ae"ulllulators,
- - of the forging press, 10, 107, 108, Il6
IlO, 183 Specific pressure, 5, lt3, 76
Rectangular columns, 263 Spring packing, ,52
Relief pin, 161 Square columns, 263
- valve, 13ii, 1153, 1.57 Stage intensificr, 103
278 L\'DEX
Stalk guiding of moving croRRhcad, 30, Upsetting, 118, 121,221,243, 244

56,59,219 ~ speed,4
Standard dimensions of hydraulie
equipment, 195 Values for forging presses, see list of
Standard dimensions of pumps, 87 tables
State of rest, 190 Valve components, 86, 154, 158
~ control, 151
Steam consumption, 179, 181,211,218
~ drive for control valves, 180_ ]{)7
control, 170, 178
hydraulic forging presses, 8, 21, 58, - - for prefill val ve, 152, 1(i[)
~ housing, lfi3, lfi8
80, 83, 8~ 99, 152, 17~ 17~ 187,
211,218 - lift diagrarn, 150, Hi4
intensifier, see intensifier - -, measuring of, Hil, Hi2
~ opening, see tlo\\' area in valn's
operation, 22, 85, 155, 170, 214
pressure, 10, 99, 155 - stroke, 86, lii7, 161, Ui2, W4, 171
pullback, 65, 178, 187 Valves, high-pressure shutoff, 14fi
speed, 172 - for oiI operation, 141, 151, li4
valve, 172 - for steam operation, 11i2, !7U
~,overflow, 136
Stresses in cylinder wall, :m, 40
~, prefill, H,2
--, signs for, 39, 44, 56
Stroke-dependent control, 168, 170 -, pump, 8fi
Support on consoles, 14, 17, 68 -, steam, 173
~ on foundation, 14, 17,37,64,68 Veloeity head, 152
Switching frequency, 120, 126 Vent serew, 53, 1i4, 1;)8
Symbols for control componcnts, liiO Viscosity, 7
~,kinematic, 140
Table drive, see shifting table Volume of accumulator, 120, 122

Temperature of oiI, 138 of aiI' vesse 1, 1:~2
Temperature of water, 136, 138 ~ of reservoir, 138, 13S
Theory of deformation, 40, 44
Three-cylinder press (see also presses), Wall roughness, 140, 141
11, 12, 60, 212, 218 - thickness of accurtlulator bottlcs, IlS
Three-way cock, 148 - - of aiI' vessels, 132
Throttle valve, 187 - - of eylinders, 38
Throttling, effect of, 8, 1:36, 138 - - of high-pressure piping, 142
for cushioning, 53, 103, 187 - - of lo\\'-pressure piping, 14(;
~ for speed control, 10, 63, 66
\Vater eharaeteristics, G
~ hammer, 53, lUi, 130, 132, IDO, 217
-- rod, 53, 103
Tie rod, 37, 266 ~ level, 116, 118, 124, 132
~ ~ in the aecumulator, 124
Timing, 168
'rools for closed-die forging, 246 - ~ in the aiI' vesseJ, 131
~ operation, (i, 77, 99
Trinuning presses, 243, 255, 256
~ temperature, 13ti
-- -, main dimensions, 255
Triplex pump, see pumps \Vear of paeking, 4H, (iO, 85, lii), 1](j
Turning device, 224, 229 - of valves, 38
'rwo-column design (see also prcsses), Wheel disks, 24ti, 250, 254
11, 13,30,66 - disk rolling miII, 243, 24li
~ rims, 246
Two-cylinder press (see also prcsses),
12, 60, 184, 212, 218, 220 Wobbler disk, 91)
Two-valve control, 149 \V orking motions of preSA, 14/{, 149
~ speeds, 1, 9, 10, 77, 221
Types of press construction, II
~ ~, control of, 78, I G2
Upper crosshead, 12 - - of cxisting presses, fi!l, 70, 77, !lI,
-- - translatory motion, 28, 30 114, 192
LIST OF TABLES
1. Weights and Dimensions of Ingots ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. lUain Dimensions of Forging Presses of Four-Column Design. . . . . . . . . . .. l;,)
3. l\J!ain Dimensions of One-Piece Shifting Tables and for Ejecting Devices
for Four-Column Forging Presses ................................... 22
4. Colunm Diameter for Forging Presses of the Four-Column Design ...... 31
5. Dimensions of Buttress Threads for Columns .. . . . . . . . . . . . . . . . . . . . . . .. 34
(j. Dimensions of Packing Chambers for Lip Packings ................... iiO
7. Dimensions of Piston Rings and Piston Ring Packings . . . . . . . . . . . . . . . .. 52
S. lUain Dimensions of Single-Frame Forging Presses. . . . . . . . . . . . . . . . . . . .. 7(;
9. Delivery and Coefficient of Uniformity u of Piston Pumps ............. H3
10. Standard Dimensions for Pumps ................................... 87
Il. );lain Dimcnsions for Pumps and l<'orging Efficiency of Directly Driven
Presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 91
12. lUain Dimensions of Existing Intensifiers of foîteam- and Air-hydraulic Forg-
ing Presses....................................................... lOI
13. Dimensions for Accumulator BottIes ................................. 119
14. Dimensions for Forging Presses and Power Fluid Stations ............. 122
Iii. Comparison between Accumulator Drive and Direct Pump Drive ....... 123
1(;. Specific Gravity and Kinematic Viscosity ............................ 141
17. Coefficients of Friction c of Pipe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 142
18. Seamless Steel Pipes for High-Pressure Lines in Forging Plants . . . . . . . .. 142
19. Dimensions for Pipe Connections ................................... 145
20. Dimensions of Pipes and Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14()
21. Dimensions of High-Pressure Shutoff Valves .......................... 148
22. Specifications for Diagrams ........................................ 193
23. Standard Values for Dimensioning of Hydraulic Units ................ , 195
24. Main Dimensions of Mobile Manipulators ............................. 2:{4
25. Maill Dimellsions for Track-bound All-hydraulic Manipulators .......... 23H
20. lVlain Dimensions for Trimming Presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 255

Ernst Müller (Auth.) - Hydraulic Forging Presses-Springer Berlin Heidelberg (1968)

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Ernst Müller (Auth.) - Hydraulic Forging Presses-Springer Berlin Heidelberg (1968)

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Hydraulic Forging Presses

With 225 Illustrations

Springer-Verlag Berlin Heidelberg GmbH

Al! rights reserved, especially that of translation into foreign languages

Titei Xr. 1346

Duisburg, June 1968

PRINCTPLES OF FORGING P}{ESSE~ ............................... 2

CHAPTER 1: FORGIXG PRESSE~................................... 1:3

CHAPTER II: PImSSURE FLUlD INi-lTALLATIONS FOR FORnINC

CHAPTER III: CONTROLR FOR FORCmm PRERSES ................ 148

CHAPTER IV: EXAMPLES OF DESIGN AND CALCULATION ........ 195

PRINCIPLES OF FORGING PRESSES

The size of the effective working area Aw elepends on the forging

1) SIEBEL, E.: Die Formgebung im bildsamen Zustande, Diisse ldorf: Verlag

188 1200 1600 1.100

178 1350 1980 1'IIJ0

'100- eZ Il Z7S0 .%00 1S70

900- 3SJ 3'1 JJ 7800 10'100 18S0

It is for this reason that usually the deformation resistance Rd = 8,

of 2,000 oF would require Ra = 7,000 psi. At extremely low upsetting

mation resistance, however, increase::; considerably with progressivc

If G is effective in the operating direction as is thc case with ali

b) Ingots and Forging Dies

Fig. 3. lflat alltl V-,liC8 (8ce table 2, p. 15).

The bearing surfaces are made to a width-Iength ratio of usually w: l

surfaees is provided in order ta inerease toollife. For this purpose, the

}'jg. 5. ]:'orgillg of a rhig on a G,{)On-toll l1TrS~:i.

regard to the running

respectively, a fly-wheel may be incorporated, preferably on the fast-

fluid to the main cylinder, thus wasting a considerable amount of accumu-

guiding of the moving platen while three-cylinder presses render possiblc

The daylight dimension c is composed of

IJrcss Column s F orging di cs

550 32 70 55 35 1 : 0 .64 28 x 7 1:4 5,700

1. Bottom or Base Platens

1) As rcgards table dimcnsions sec table 3, p. 22.

When designing base platens, a favorable blending of the different

Seclion C-[) Platen C/WJ - SCc!iOfi A -lJ

}'ig. 1:;. ShO]J usscmbly of forging ]Jreso shown an fig. 12.

contamination of the sliding surfaces by scale and other foreign matter.

multiple-piece shifting table, however, is the exposurc of the guide ways

large presses , hydraulically. Frequently, cogging is provided alongside

suitable because of contamination. The electric table drive is only used

advantage of this arrangement is the precisc speed control as compare(l

Prc_s Tablc arca

2,750 240x 67 160 80 88 140 5 44

It is practical to arrange the ejecting device in such a way that the

favorable modifications to the original press construction. Proven dimen-

platen are distorted by several sixteenth of an inch. Frequently thcsc

3. Columus aud Nuts

If, however, an eccentric forging resistance occurs according to

an additional bending stress is applied to the columns which, in man)"

1) J. Iron Steel Inst. 161 (1949) Febr. Issue.

of chains suspended from the moving crosshead protect the columns

The following calculation example for a four-column press is to only

----- !1omer7/.r ilS pe!' fig.Z3c fo!' compllf'ison

Together with the column tension force P t = ~- , a corn bincd nominal

and for the four-column press with P 2 = 2 P:

The assumcd 10ading condition represents the unfavorable limit for

reasons, led to the preferrcd construction of the moving-frame typc

Table 4. Column Diameter for Forging Presses of the Four-Column Design

Pre 350440'55°170088011,1001,3801 ,76012200 2,7503,5004,400

The heavy presses in particular are therefore equipped with a column

As the load limit, i. e. the fatigue strength 8fmay be closely approached