FORMING

The new SF350-6 model, a six-station part former offering a maximum cutoff diameter of 28mm and 3,000kN of forging pressure, will be initially delivered to Japanese automotive component makers who make up Asahi Sunac's main customer base. The SF-series part formers include advanced features designed to allow the cold former to forge workpieces having a higher level of dimensional precision than ever before. This has been made possible by the company's proprietary ram slide design which uses a zero-clearance fine slide system, a fine feed system which uses a griper mechanism to obtain highly precise feed lengths, and a rigid high-speed fine cutoff system which significantly improves the quality and uniformity of the cutoff slugs. These innovations contribute to the part former's ability to produce near net shape workpieces that require less post-forge processing. Users of Asahi Sunac part formers have reported that, in addition to producing complex workpieces to amazingly high tolerances, they are also experiencing longer tooling life.
Asahi Sunac's net-shaping concept aims at reducing the amount of machining needed to finish cold formed blanks through the ability of the part former to forge blanks to a higher level of precision. The net-shape part formers also offer the benefits of a more operator-friendly working environment, increased automation, less energy consumption, automatic adjustment and monitoring systems, and robotic tooling changeover which combine to form a complete forging system that can lower costs across the board.
In Order to assess the performance of the new SF350-6 part former, Asahi Sunac customers chose two blank types for the company to test tun. Both were pierced (hole through) automotive components which demand a high level of precision and quality. One machine Operator was able to replace all tooling in less than one hour by setting up the die and punch blocks off the machine, installing the tooling, and starting up the machine for a production run without doing any adjustment work inside the former.
Asahi Sunac cold formers use a block-type tooling changeover system which has gained wide user acceptance due the high level of dimensional repeatability it provides for the blank. The fine slide system uses a ram and slide designed to suppress off-center ram movement. This improves dimensional repeatability after the tooling block is replaced by keeping the ram an Center to maintain blank precision.
A special jig has been designed and fabricated to allow the punch block and die block to be set up an the bench off the former. Each tooling block can be installed to the jig, and the Asahi Sunac PC Monitor (which is now being marketed by the company as a product in itself) used to verify the alignment of the punch block relative to the die block using numerical values. Because the PC Monitor allows the punch and die blocks to be installed in the former after having their alignment verified by numerical values off the machine, the tooling for the next job can be set up off the former while it is running, and then installed for the next production tun without the need to align the punches after they've been installed in the former.
Asahi Sunac also offers the Multicontroller, a proprietary changeover and process control computer which can significantly reduce changeover time by automatically executing feed length, kickout, transfer cam timing, and other setup adjustments simultaneously for the next job.
Also reducing changeover time is the company's fine feed system which eliminates the conventional job of replacing the feed rollers when a new wire size is to be run. The system uses a new grip-feed mechanism which replaces the feed rollers, and which adapts to different wire sizes without the need to replace components.
Prospective purchasers of the new SF-350-6 part former at the demonstration meeting witnessed how the machine was up and running producing high-precision workpieces after a tooling changeover and alignment operation that took only an hour. The precision mechanical systems and QTC system (Quick Tooling Changeover) play a part in the SF-350-6 ability to provide a high level of precision repeatability.
Orders for the SF series 6 and 7-station part formers are solidifying along with production plans. Asahi Sunac is committed to satisfying the needs of each individual customer with continuing development of the net shaping concept which is allowing the cold former to produce a wider range of value-added products. The company is committed to supporting the further development of the forging industry and disseminating Information an the tatest technical developments.

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