August 2021 Volume 3

EQUIPMENT & TECHNOLOGY

Recognizing that the graphite oil can be the most objectional ingredient of hot brass forging, the programmable features of a servo linear motor systemgreatly reduce the frustration that can arise from graphite dosing and air cooling. Unfortunately, graphite remains a messy necessity to the process and regular clean-up is required. In this system, the forging dies are relatively small and inexpensive. Most forging houses will also have a five-axis vertical machining center to produce these dies or have a local tool & die vendor with this capability. Although certain coatings can prolong die life, the lower die cost generally does not benefit directly from coating, unless the part has significant complexity causing turbulence in the forming process. Die changes are relatively simple and can be accomplished in less than 30 minutes. This is a meaningful advantage over typical mechanical presses that require upwards of two hours for complete die change. The die change for the Neotecman press only requires one person and generally the operator performs this function. While brass continues to be the main focus of this press technology, other light metals are produced regularly. Many aluminum and copper alloys forge well in a side core hydraulic press. Optional induction furnace technology will soon broaden the alloy potential. There are five sizes and styles of the Neotecman press, producing brass forgings up to 7.5 pounds. The raw bar input diameter range is from 12mm to 65mm. The challenge in the North American market is not so much updating older forging technology but converting existing production from casting and bar to forgings. With the simplicity of the new technology, foundries assimilate to this style of forging

seamlessly. However, significant brass usage at the screw machine producers makes conversion from bar an interesting possibility. Near net shape forgings reduce the amount of material used per part and greatly simplifies the machining by eliminated much of the roughing passes required from bar or shaped bar. When supplying rotary transfer machines to produce the same part from bar or forging, it is not unusual to spend over one million dollars less to machine the forging due to fewer machining units and smaller footprints. Forgings do not require expensive bar feeders and saws at machining and therefore, save the space that would be occupied with bar feeders. The grain structure of the forging is also superior to bar that can contain longitudinal stringers and other inclusions that lead to cracking and failure. The forging will machine easier and more consistently, providing lower perishable tooling costs. The move to forgings, or improved forging technology, provides several benefits worth your investigation. ■ Mike Hoff (Mr. Brass) Email: mike@btbna.com Phone: 937-238-2820 www.umsmfg.com

FIA MAGAZINE | AUGUST 2021 12