HYDRAULIC POWDER PRESSES
Cost-effective and flexible
THE SMS GROUP IS A GROUP OF GLOBALLY OPERATING
COMPANIES IN PLANT AND MACHINERY CONSTRUCTION
FOR STEEL AND NON-FERROUS METALS PROCESSING.
WE COVER EVERYTHING FROM PIG IRON PRODUCTION
TO METALLURGICAL PLANT, ROLLING MILLS TO STRIP
PROCESSING LINES, TUBE MILLS AND FORGING PLANTS
TO THERMAL TECHNOLOGY – COMPLETE WITH ELECTRICS
AND AUTOMATION AS WELL AS SERVICE.
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PRODUCT RANGE
IRON MAKING
TUBE AND PIPE PLANTS
LONG PRODUCTS PLANTS
ELECTRICAL AND AUTOMATION SYSTEMS
PRODUCTION
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METALLURGY PLANTS AND
ENVIRONMENTAL TECHNOLOGY
FLAT ROLLING PLANTS
STRIP PROCESSING LINES AND
FURNACE TECHNOLOGY
FORGING PLANTS
TECHNICAL SERVICE
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HYDRAULIC
POWDER PRESSES
FORMING THE FUTURE
The production of complex sintered compacts of
consistently high quality and on economic terms
are the demands facing the operators of powder
presses. The parts produced are used predominantly
in the automotive industry, but also in the electrical
appliances industry and in general machine engineering. The industry finally recognised the benefits
of powder metallurgy in the 1950s, and since then
the technology has enjoyed rapid growth.
The development of new materials
and growing demands for “near-netshape” are now presenting new
challenges, but at the same
time opening up new and
trendsetting opportunities for
the powder press technology.
LEADING IN PRESS
TECHNOLOGY
SMS group has played a leading role in the further development of the press technology
in powder metallurgy with
its innumerable innovations
from the very beginning.
The company has more than
60 years’ experience in powder
press technology. On the basis
of this experience, standards
were set in the machine engineering of the powder presses
through continuous research
and development. For example,
presses with PLC and CNC
systems were produced as
early as 1985, followed in 1990
by a fundamental optimisation
of the valve, path and pressure
measuring technology allowing presses with press forces
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from 600 kN to 16,000 kN to be produced. A further
trendsetter was then the “controlled punch adapter”
(CPA) technology patented by SMS group. In addition,
the press concepts were expanded up to 25,000 kN
and the complete part handling technology was integrated into the press. The experts from SMS group
use all their experience and knowledge to build new
plants and modernize older designs – so that even
decades later plant operators can still produce in line
with market requirements.
left: hydraulic powder press with first CNC
right: hydraulic powder press, old design
SMS group is still today the market and technology leader, providing flexible and future-proof
solutions with continuously optimized processes.
 High dimensional stability
 Uniform density
 No cracking of the compacts
 Near-net-shape forming
 Large number of punch levels for complex
geometries
 Minimization of mechanical finishing
Hydraulic CNC
powder press
HPM 800 E5
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CNC PRESS TECHNOLOGY
TAILOR-MADE PRESSES,
FLEXIBLE APPLICATIONS
With the hydraulic CNC powder press and controlled
hybrid press (CHP) product range, SMS group is
able to offer the right solution for practically all applications. The customer can choose from two press
ranges, each with different types and press forces,
allowing individual configuration to meet the specific
requirements. While hydraulic presses are based
completely on a hydraulic system, the hybrid press
series employs a mechanical/hydraulic drive system
for the upper ram enabling the advantages of a highspeed mechanical system to be employed extremely
efficiently together with the precision of a hydraulic
system. Furthermore, the SMS group presses are
characterized by a compact form as a four-column
press with a low overall height.
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OUTSTANDING TECHNOLOGY,
INTELLIGENT OVERALL CONCEPT
The CPA process technology developed and patented by SMS group and the excellent implementation
of the hydraulic-mechanical drive were commended
with the EPMA Award. Compared with other systems, the hydraulic CNC positioning during the
whole press cycle – and in particular in compacting
position – impresses with its high precision, product
quality, reliability and gentle operation. Coordinated
operating heights and arrangement of powder filling,
adapter changing systems and part handling equipment round out the overall SMS group concept.
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Die-set change system for hydraulic CNC powder press
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Die-set trolley
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Headplate turning device
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Tool change station
BENEFITS AT A GLANCE
„ Press forces from 600 kN to 25,000 kN
„ Repetition accuracy of ± 0,01 mm
„ Product changing in less than 20 minutes
(thanks to short tool and adapter changing
times)
„ Energy saving thanks to new hydraulic
concepts
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CPA – CONTROLLED PUNCH
ADAPTER
UNIQUE POWDER PRESS PROCESS,
UNIVERSAL POSSIBILITIES
The heart of the hydraulic CNC powder presses and
the hybrid presses is the controlled punch adapter
patented by SMS group. Equipped with up to 12
axes, it permits extremely flexible operation for the
production of highly complex sintered parts. With
the CPA technology, several punch levels interact,
controlled fully automatically and precisely by the
CNC system. SMS group offers a broad range of
adapter changing systems – from simple to fully automated. Furthermore, the controlled punch adapter
has a well planned and easily accessible design for
simple tool changing.
PROCESS ENGINEERING OF THE
HIGHEST STANDARD
The powder is brought into the desired geometry by
controlled movement of the punches – and allowing
for their interaction – initially without applying the
compacting force. This creates a basic precondition
for the later uniform density of the compact. This is
followed by the coordinated press compacting process. With the telescopic arrangement of the cylinders, each CPA axis is guided extremely precisely
and can transmit high compacting forces. Thanks to
the hydraulic CNC axes, the force of all the punches
is applied uniformly and the punch expansion is compensated, particularly during the relief phase.
The result: Compacts without micro-cracks. Furthermore, the compacting process is made far more
precise and controlled for a lasting high productivity
and product quality.
Press and CPA with 12 CNC axes
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CPA 1200
BENEFITS AT A GLANCE
„ Up to 12 axes (optionally even more)
„ Forces in the axes from 600 to 10,000 kN
„ No risk of cracking in the compacts
„ Optimum flowing powder transfer thanks to
uniform punch speeds
„ Hydraulic pressure relief of the punches on
CPA 350
both sides after reaching the compacting
position
„ Compensation of the elastic punch deflection
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COMPACTING PROCESS
1. Filling
2. Underfill
3.1 Start powder transfer
The compacting operation using the CPA method by
SMS group is particularly efficient. It comprises seven
finely coordinated steps to guarantee optimum product quality.
1. FILLING
For powder filling, the lower punches are already
pre-positioned in relation to each other.
2. UNDERFILL
To prevent powder losses when the upper punches
contact the powder, the die form is lifted.
3. POWDER TRANSFER
The powder is displaced by individual punch move-
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3.2 Powder transfer
3.3 Transfer position
ments without pre-compaction. The powder transfer
position is reached when the powder displays the
uncompacted partial contour.
4. COMPACTION
The powder is now compacted in a controlled manner
– taking precise account of the parameters stroke,
time and pressure. In the process it is crucial that
all press punches reach the compacting point simultaneously.
5. FORCE REDUCTION
To compensate punch spring-back and rob the pressed
part of its rebound forces, the upper and lower punches move up and down individually and concerted.
4. Compaction
5. Force reduction
6. Withdrawal
7. Release
6. WITHDRAWAL
The compacted part is carefully exposed and at the
same time held by the punches – thus preventing
cracks in the part.
7. RELEASE
Finally, the punches are moved back into their initial
position. The finish compacted part is released and
can be removed.
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SAVINGS IN COST AND TIME
COMPLEX PARTS IN NEAR-NET-SHAPE QUALITY
The more precise the forming contour of metal powder parts, the less further machining is necessary. The
resulting savings potentials in time and costs are enormous. The CPA compacting method from SMS group is
far superior to conventional compacting methods as far as near-net-shape parts are concerned.
Compacting point
Compacting point
FORCE CURVE WITH LINEAR
COMPACTING SPEEDS
The diagram shows the compacting speed (depending on compacting stroke) up to the compacting
position of the upper and lower ram systems. All
the press axes have then own compacting speed
adapted to the stroke in order to finally reach their
compacting positions simultaneously with high
counter-force. Exponentially increasing forces of the
press axes up to compacting position with constant
compacting speeds.
Transfer position
Transfer position
Stroke
(mm)
Stroke
(mm)
COMPARISON OF THE COMPACTING
METHODS
The diagram shows the difference between the CPA
compacting method and conventional compacting. At
the start of the controlled compacting movement, the
two methods are identical with respect to proportional
speed of the lower punches to the upper ram speed
(points 1+2 in the diagram). With the conventional
compacting method with fixed stop, a deflection point
is reached with the upper ram speed being followed
due to the insufficient counter-force (point 3). The
compacting position is then reached prematurely on
the mechanical fixed stop with final compaction being
effected only by the upper punches (point 4). With the
CPA compacting method, on the other hand, the process is linear and uniform with all the controlled press
punches reaching the compacting positions simultaneously with high counter-forces (point 5).
Compacting position
Compacting position
HK4 (AR4)
HK4 (AR4)
Time (sec)
Time (sec)
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1
2
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3
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Time (sec)
4
Time (sec)
Upper ram curve
DieUpper
curveram curve
Lower
punch curve
Die curve
Lower
punch
curve
(conventionel)
Lower
punch
curve
Lower punch curve (conventionel)
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HK5 (AR5)
HK5 (AR5)
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Force
(kN)
Force
(kN)
Stroke (mm)
Stroke (mm)
HK5 (AR5)
HK5 (AR5)
HK6 (AR6)
HK6 (AR6)
HK6 (AR6)
HK6 (AR6)
HK4 (AR4)
HK4 (AR4)
Stroke (mm)
Stroke (mm)
NEW APPROACH FOR
FUTURE TECHNOLOGY
Powder presses produce predominantly components for the automotive industry. Not so at Gobal
Tungsten & Powders (GTP). For this U.S. based company SMS group adapted its press technology
to a completely new application in a very short time period. With its HPM 1600E5i GTP manufactures
components for fuel cells. “SMS group supports us in developing a new market in the area of Green
Technology. Success in this process requires a combination of technology and efficiency which we
have found with SMS group”, says Mike Cuddy, Procurement Manager, GTP.
The HPM 1600E5i impresses with its precision, speed and high process reliability. The optimized hydraulics warrant minimum energy requirements. This is how SMS group understands
customer focus.
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PROCESS AND
QUALITY CONTROL
THE INTELLIGENCE OF THE PRESSES
The CNC system of the powder presses has a clearly
structured and easy-to-use operator interface. Machine
operators are therefore familiar with the machine and
its functions within a minimum of time. Easily comprehensible programming applications, actual value/
nominal value real-time analyses, fault displays and
diagnostic functions are available. The process data
for repeat parts can naturally be saved in a database,
thus shortening the set-up time in the future.
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BENEFITS AT A GLANCE
„ Easily comprehensible visualization
„ Fully automated process control
„ Fully automated quality control
„ Statistical evaluation for process or
production optimization
Oscilloscope diagram for all functions
Operation flow
Actual machine values
Production values
AUTOMATED QUALITY FUNCTIONS
When data are entered, the CNC system performs
a plausibility check, thus helping to avoid operator
errors. It provides all the operating data for the compacting process, monitors the sensors, compares
actual and nominal values and records all the vital
process data for quality assurance as part of the
statistical process control (SPC). With the continuous quality documentation, plant operators can
meet the demands of the relevant standards or the
customer’s specifications without additional work.
Parameters monitored are i.a. the position and force
of the top and bottom punches and the part weight.
The compacting force curves of all the press axes
involved in the process are also monitored and
recorded in relation to their preset tolerances.
The statistical evaluations serve for both process
and production optimization on the machine and
for quality documentation. The CNC system can be
integrated into a network so that the recorded SPC
process data can be forward directly to the responsible employee.
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SYSTEM SOLUTIONS
MODULAR COMPONENTS,
HARMONIZED INTERFACES
SMS group offers complete system solutions for a
press centre from a single source. The advantages:
The modular components in the mechanical equipment
and software allow gradual expansion and individual
adaptation. The interfaces in the electrical and automation system and in the mechanical equipment are
harmonized so that smooth and productive operation
is immediately assured. After evaluation in advance,
SMS group can also integrate existing equipment into
an overall concept.
PERIPHERALS
 Controlled punch adapter (CPA) with or without-
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punch prelift and conventional multi-platen
adapter
Adapter transport equipment with integral
clamping and positioning device
Press tools of tool steel and carbide metal (die,
punches, mandrels)
Handling equipment such as small manipulators,
pneumatic or hydraulic pick-and-place units,
conveyor belts and deposit systems
Measuring and testing equipment for checking
the tolerances of the compacts
Magazining devices such as turntables, pallets,
indexed feed and removal systems and further
logistics components
Hydraulic powder press line HPM 1000 E5
Hydraulic powder press line CHP 160
Compaction force
Line of types
Hydraulic CNC presses
600 – 2,000 kN
HPM 60 E5
HPM 150 E5
HPM 200 E5
2,500 – 3,500 kN
HPM 250 E5
HPM 350 E5
5,000 – 8,000 kN
HPM 500 E5
HPM 650 E5
HPM 800 E5
10,000 – 17,000 kN
HPM 1000 E5
HPM 1500 E5
HPM 1700 E5
20,000 – 25,000 kN
HPM 2000 E5
HPM 2500 E5
CHP 160
CHP 250
Hybrid CNC presses
1,600 – 3,200 kN
CHP 320
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FIELDS OF APPLICATION
AND REFERENCES
UNLIMITED POSSIBILITIES
Powder presses from SMS group permit a broad
product spectrum to meet present-day and future
demands. High-strength materials and even “green
products” are increasingly being produced on the
machines. These include, for example, surface-contoured interconnector plates, the key components in
high-temperature fuel cells. Thanks to the flexible
modification and cost-effective expansion possibilities of the presses, plants operators can be sure of
investing in a future-proof technology. That is why
leading compact manufacturers rely on SMS group
as partners.
EXCERPT FROM THE
REFERENCE LIST
 Ames Group, Spain
 Chepetsky, Russia
 DAAZ, Russia
 Federal Mogul, England, France and India
 Forschungszentrum Jülich, Germany
 GAZ, Russia
 GKN Sinter Metals, USA, Canada and Germany
 GTP, USA
 Han Dok, Korea
 Miba, Austria
EXAMPLES OF POTENTIAL
APPLICATIONS
 Compacting of complex metal powder parts
 Production of compacts from powder materials
such as iron alloys, ceramics, metal oxides, carbide
metal, ferritic and graphite powders
 Sinter forging
 Composite compacting
 Sizing
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 Netshape Technologies, USA
 Ningbo Tongmu, China
 PMG Füssen, Germany
 Plansee SE, Austria
 Schunk Group, Germany
 Stackpole Canada Inc., Canada
 Toyota Motors, Japan
 University Hanover – IFUM, Germany
 University Kassel, Germany
TM
© Plansee SE
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NOTES
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SMS GROUP GMBH
Business Unit Forging Plants
Powder Presses
41069 Mönchengladbach
Germany
Phone:
+49 2161 350-1691
Fax:
+49 2161 350-1778
[email protected]
www.sms-group.com
The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as
described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to
deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.
E1200.07/15 en · Printed in Germany
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