Cold forging is a very popular form of metalworking. It does not require many years of mastering the art of a blacksmith, the equipment of a bulky, traumatic and fire hazardous traditional forge. Consider machines for cold forging metal Azhurstal.
Rolled metal is formed in an unheated state by applying pressure. Many novice home craftsmen make cold forging devices on their own. This is fully justified at the stage of mastering the technology, making decorations for your home and site, and analyzing the market.
But if you decide to start a business in this area, then it is better to think about purchasing industrial cold forging equipment.
Cold forging capabilities
The cold forging method is based on the physical phenomenon of plastic deformation of a metal workpiece under the force applied to it. The workpiece is bent, stretched, twisted, flattened or cut, acquiring the shape desired by the master.
Forged rocking chair 
Using this forging method, do:
- rods and lattice decorations;
- decor elements;
- decorations for landscape design;
- furniture details.
Based on standard elements, passionate craftsmen are constantly developing new designs for their products.
Types of machines Azhurstal
Artistic forging machine "AZHUR-1M"
Machine tools manufactured by Azhurstal are divided into several types:
- Universal bending machines for cold forging openwork allow you to produce curls, volutes and almost all figures used in artistic forging.
- Rolling machines are designed to form a relief pattern on the edges of a bar or shaped steel, as well as to produce a coiled pipe with a variable coil pitch.
- Vertical and horizontal presses developing forces up to 100 tons.
- For preparatory operations: a cutting machine for cutting solid and profiled rolled products and a machine for transverse cutting of rolled metal.
Machine for artistic forging "Azhur-3M"
Azhurstal can, at the request of the customer, complete universal machines:
- portable forges for heating the ends of the blanks when performing complex elements;
- a large number of special equipment - snails, rollers, mandrels, etc.
Artistic forging machine "Azhur-1"
This allows you to expand the capabilities of the equipment or increase maximum size and complexity of the manufactured elements.
Manufacturing technology of openwork forging on the machine
The technology for the production of products on the Azhurstal machine for artistic forging captivates with its simplicity. The designers of the enterprise did everything to facilitate the work as much as possible and achieve high quality.
Most of the machines are equipped with automation, and for the production of a curl or volute, the user just needs to install the appropriate equipment, set the dimensions, fix the workpiece and press the feed button. The Azhurstal machine itself regulates the feed and pressing force of the forming rollers and will stop at the end of the operation.
Pros and cons of technology
The main advantages of cold forging technology are:
- Ease of use. There is no need for long training.
- Low labor intensity.
- Identity of received serial products.
In addition to the advantages of the method, there are also disadvantages.
- Limited product options. It is impossible to forge a flower or a leaf, not to mention figurines.
- The limited form of blanks is a bar, strip, hollow rolling.
The method is perfect for the production of small and medium series of the same type of parts.
Necessary materials
The list of materials used for cold forging includes
- The rod is round.
- The rod is square.
- Tubes are round or square.
- The strip is metal.
- Profiled rental.
In addition, you will need:
- grinder or cutting machine for cutting blanks to size;
- welding machine;
- metalwork tools - vise, clamps, hammers, tongs, etc.
In the workshop or under a canopy, you need to equip a spacious, level place for assembling elements into a finished structure.
Features of maintenance of machines for openwork forging
Machine tools produced by Azhurstal are distinguished by their reliable design and high resource. In order for the unit not to fail during the execution of a responsible order, it is necessary to follow the regulations for its maintenance.
Daily maintenance consists of an external inspection for mechanical damage and checking the tension of the drive belt, as well as the reliability of fastening the equipment and executive bodies unit.
Every 1,000 hours of operation, the gears and bearings should be checked for lubrication, and if the lubrication is worn out or hardened, re-lubricate. It is also necessary to check the oil level in the transmission and add it if the level is below the mark. At the same time, the safety of the wiring and all electrical equipment should be checked.
In the presence of a large fleet of equipment, it is possible to conclude an agreement on maintenance and repair by authorized dealers Azhurstal
Features of various machine models
Azhurstal offers a wide range of equipment and accessories for all manufactured units.
The product line begins with the compact "Azhur-mini". Despite the low power - 1.1 kW and modest dimensions, it copes with a bar up to 16 mm. This is a great choice for the beginner.
The Azhur-1 station wagon has three times more power and a wider choice of additional equipment and accessories for it. It is already designed for professional use and allows you to produce up to 5000 bent elements per month.
Rolling machine "Azhur-2" is designed to form a three-dimensional pattern on the strip, round and rectangular rolled products.
Universal "Azhur-universal" combines both bending and rolling unit. This is already a small technological complex that can significantly save working time.
In addition to them, "Azhur-4" is also supplied to obtain a twisted pipe with a different pitch of turns.
The presses are produced in three versions: horizontal "Azhur-3", vertical "PV-100" and vertical forging press - "Azhur-7". They are equipped with an electromechanical or hydraulic drive and develop a working force of up to 100 tons.
Azhurstal equipment covers almost all conceivable needs of manufacturers in the field openwork forging.
To write an article about novelties in forging equipment I was moved by chance. Recently, I ordered a lattice for a window in one workshop. Word by word, I got into a conversation with the blacksmith, a young man of about thirty, Alexei Baryshnikov. First, the conversation turned to small business, and then quietly moved on to technical topics.
“For the time being, in our workshop we specialized mainly in welding and cutting metal - circle, corner, square,” said the blacksmith, “but there were not enough forged elements. So clients left for neighbors who have a hammer. Recently, we also took an old 75-ku hammer. Completely put in order, removed backlashes, put up cranes according to the passport. But you still have to work extremely carefully with the pedal, constantly focus on the firing pin. You make a mistake from fatigue, you don’t keep track, and instead of lightly hitting the workpiece, you strike such a blow that the almost finished part is flattened. The guys say - all because I'm not an experienced blacksmith. Is there really no normal hammer that would regulate the amplitude of the striker itself?”
Frankly, this problem surprised me. Indeed, does our industry really not produce such equipment that, on the one hand, would be affordable for small businesses, and on the other hand, would be so convenient and reliable in operation that even a beginner could easily work on it?
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Yandex search led me to the factory website "Azhurstal", and then I had a conversation with the commercial director of the Azhurstal group of companies, Oleg Pavlov, who answered all my questions.
Yes, we have begun production of such a machine as "Azhur-7". It can also be used to manufacture many elements that are usually made with a hammer,” said the commercial director. - But in working with a hammer you need to have great experience. Whereas a person who has never previously been engaged in artistic forging, no special permits or ranks are required for operation. A person can learn how to work on a machine in 2-3 days. Also, do not forget that this equipment is designed to produce the same elements in large quantities. Elements can be used both in the production of our own forging, and sold by the piece.
Apparently, this was exactly what I was looking for for Alexei Baryshnikov.
- Tell me, Oleg, what kind of parts can be made on "Azhur-7"?
What about artistic forging by hand by 90%, depending on the use of molds standard or custom-made by the equipment buyer, the execution of the element is limited only by the maximum stroke of the slider 210mm and the size of the mold, approximately 200*50mm.
In other words, "Azhur-7" covers almost all the needs of blacksmiths from private workshops. And how reliable is Azhur-7? What components and mechanisms make the machine original and durable?
Our company has been specializing in the production of high-speed hydraulic presses for a long time, now there are three hydraulic press these are: Azhur-3M, PV-100 and the new Azhur-7, in the production of which only high-quality Italian components for the hydraulic system and convenient controls are used - all presses are equipped with foot pedals.
Is there a guarantee? What forms of service (ease of repair and affordable spare parts) does your company offer? After all, it happens that the machine breaks down, and spare parts need to wait for months.
Warranty 12 months. Our company has a department technical support operation, commissioning, warranty and post-warranty service. The engineers of this department will not only give qualified advice at any time of the day, but will also be able to leave at any time convenient for the client to carry out work. Since all original parts and accessories are made in our factory and always in stock, you won't have to wait for months for them, which is not the case with other manufacturers.
- What is its technical "zest" and competitive advantage before other similar (imported) machines?
The press was created with clean slate, taking into account the requirements of professional blacksmiths, which many elements are made by hand or with a hammer, but this takes a lot of time. This is the first press designed specifically to perform such art forging elements and at the same time very affordable for small and medium businesses - RUB 410,000, including has a force of 100 Tf. There are no analogues as such, or we could not find information about them, no one produces in Russia. There are presses that differ greatly in size or cost at times, of course, you can make the same elements on them, but very few people can pay about 50,000 Euro for it.
Yes, the difference is significant. 410,000 rubles is not such a large amount for a small business, in any case, it is lifting, which cannot be said about two million rubles. And how does it work? What makes it convenient for forging?
Well, firstly, the press works much quieter than when forging with a hammer, and secondly, it has great accuracy and speed of manufacturing identical elements. I repeat, a person who has never been involved in artistic forging, no special permits or ranks are required for operation. A person can learn how to work on a machine in 2-3 days.
Small businesses don't stand idle. Is it possible to say about "Azhur-7": "I bought it, delivered it, installed it, turned it on and I'm working"? That is, this machine without a "headache"?
The machine leaves the gates of the enterprise absolutely ready for work, you just need to connect it to the mains and pour hydraulic oil into the hydraulic tank.
Everything that I learned from the commercial director of the Azhurstal group of enterprises, I told Alexei Baryshnikov. The blacksmith had already "worked hard" with the old hammer, so he accepted my information with a bang. And just recently, I met Alexei again, who nevertheless bought Azhur-7. The master shook my hand for a long time in gratitude, repeating: “Excellent machine!”.
“We, blacksmiths, do everything with our own hands and we know how important it is to be in demand among our citizens,” said Alexei. - Therefore, buying Russian equipment, we vote for our country. And that's very important."
Alexander Sitnikov
Machine tools of the "Azhur" series are designed for artistic forging of metal in a cold way. The cold forging method allows you to make many decorative details. Work on the machines of this line is safe, efficient and does not require special long-term training of personnel.
Cold forging capabilities
The cold forging method is a torsion and bending of rods of a certain section. The result is a set of parts from which the finished product is assembled.
Specialized machines "Azhur" allow you to perform the following operations:
- bending elements according to the template by rotation. This procedure is carried out using special templates compatible with the spindle. The role of the machine is to control the accuracy of the corners;
- the twisting of the bar takes place on a machine of the same type with additional nozzles included in the package;
- coiling of rings is carried out on a special nozzle;
- cutting of forged parts is carried out on machines of a special type - scissors. The sections of the part are displaced relative to each other, creating an even, neat cut.
Now more about the machine "Azhur" of each model.
Machine "Azhur-1M" bending
machine "Azhur-1M"
It can produce almost any popular elements used in artistic forging products:
- baskets;
- volutes;
- rings;
- peaks;
- reverse bends;
- endings;
- torsion bars;
- snails.
The power of the machine is 3000 W, it works from networks of 220 or 380 V. "Azhur-1M" works with workpieces with a diameter of 8 to 16 mm, a profile pipe No. 15 and No. 20. Torsion bars are made of 10-20 mm rod. The working shafts rotate at a speed of 7.5 revolutions per minute.
Additionally, the machine "Azhur" is equipped with:
- a power unit that operates as a drive to the forging module;
- horn for heating the ends of the bar;
- forging module with a set of eccentric rollers. With its help, the ends of the rods "goose foot", "faceted peak", "dome peak" and others are formed;
- a drum for making a “ring” part with a diameter of 114 mm from a round or square rod from 6 to 12 mm;
- snail - used to make curled elements from a profile pipe, round or square rod. Completely eliminates the appearance of creases;
- torsion - used to perform the element of the same name, comes in a set with washers and adapters.
The machine includes an electrical part, a mechanical part and a horn. Mechanical elements:
- electric motor;
- bed;
- forging module;
- reducer;
- tooling.
The electric motor through the gearbox drives the lower roller of the forging module. From here, the movement goes to the upper and middle rollers. Eccentrics are placed on these shafts; during torsion, they bend the workpiece into the required shape. The workpiece is preheated.
Some elements are created using a drum or “snail” installed on the middle shaft. To create a "torsion bar" and "basket" devices are installed on the upper roller. The heating horn is powered by a gas burner.
Machine "Azhur-2" rolling
machine "Azhur-2
The purpose of "Azhura-2" is to apply a convex ornament to a profile pipe, strip, square and round bar. The power of the electric motor is 3000 W, it operates from a three-phase network of 380 V, it can be modified for 220 V. The equipment rolls up to 4.5 linear meters per minute.
The maximum size of the workpiece in cross section, in mm:
- profile pipe 40 x 40;
- stripes 20 x 20;
- diameter round bar 20;
- side of square 20.
The shafts rotate at up to 7.5 revolutions per minute. There are two complete sets of the machine: basic and complete.
The basic package includes:
- forging module;
- power unit;
- top and bottom shafts;
- gear cage with adjustment - necessary for the simultaneous rotation of both shafts at any position of the upper one;
- guiding mechanism for the strip;
- guide mechanism for the square;
- rollers for rolling cuts in the shape of a square;
- rolling textured rollers;
- "Greek" ornament for the strip.
The complete set additionally includes:
- 37 types of rolling reliefs;
- 7 sets of shafts for rolling different reliefs on a profile pipe, square;
- horizontal straightening mechanism;
- smooth adjustment of rolling speed.
Rolling machine "Azhur" consists of the following elements:
- electric motor;
- frame welded from steel;
- gearbox with gears;
- forging module with straightening mechanism;
- electrical part.
The motor, through a gearbox with gears, supplies rotational motion to the shafts of the forging module. Here are the forming rollers. The bar passes between the upper and lower rollers and takes on the shape of the rollers. After that, the part is fed to the dressing mechanism: two balancers, which give the part a flat or curvilinear shape.
Machine "Azhur-Universal" rolling and bending
machine "Azhur-Universal"
This model is a combination of the two previous machines "Azhur-1M" and "Azhur-2", which allows you to create almost all known forging elements, process edges, roll ornaments on parts of different profiles.
The machine is offered in two trim levels: basic and complete. It works with blanks from 8 to 20 mm in diameter, strips up to 60 mm wide. The working shafts rotate at a speed of 8.5 revolutions per minute. The equipment is equipped with a 3000 W motor powered by a 380 V three-phase network. The machine is designed to work in small and medium-scale production.
Mechanical elements of the rolling and bending device "Azhur-Universal":
- electric motor;
- bed;
- two forging modules;
- reducer;
- electrical part.
Through a belt drive, the electric motor transmits the movement to the gearbox and rollers of both forging modules. Eccentrics are located on the middle and bottom rollers of the first forging module, they make parts in the form of a "blade", "spike", "houndstooth". A “snail” is attached to the outer part of the middle roller. With the help of a combination of the console and the upper roller, "torsion bars" are made.
Press horizontal "Azhur-3M"
hydraulic press "Azhur-3M"
The hydraulic horizontal press "Azhur-3M" is designed for making metal fences, gratings from a rod with a diameter of up to 20 mm, strips up to 20 mm wide. Designed for use in large-scale production.
Electric motor power 5500 W, rotational speed - 1450 rpm. Works from a three-phase network 380 V. The press creates force in 30 tons. Attached to it is equipment for making patterns: “wave”, “cartouche”, “corner”, “semicircle”, “French profile”, “yeshka”, “chervonka” and others.
The press consists of the main elements:
- base;
- gear hydraulic pump in tandem;
- electromechanical hydraulic valve equipped with safety valve;
- hydraulic tank;
- hydraulic cylinder;
- stamp with guide columns;
- oil filter;
- electrical panel.
Engine oil 403, Shell Tellus 46 is used as a working fluid. The pump assembly is protected from overloads by a safety valve. The press is installed on a hard surface made of asphalt or concrete, set horizontally according to the level.
Machine for twisted pipe "Azhur-4"
machine "Azhur-4"
On this machine, it is possible to produce twisted pipes with a diameter of 10 - 160 mm, with a given coil angle. Such an element decorates the finished product very much, it is used as a stand for a lantern, furniture, fences.
The machine produces up to 4 linear meters of twisted pipe per minute. It is equipped with a 3300 W electric motor powered by a three-phase power supply. The speed of rotation of the shafts is 18 revolutions per minute.
On the base there is a base plate with grooves (3 pcs.) located at an angle. Sliders (3 pcs.), equipped with movable brackets, are attached to the base plate. Rulers are placed on the back surface of the plate to control the movement. Each bracket is equipped with swivel plates, which rotate along the axes relative to the bracket. You can set the position of the plate using the clamp.
Rotary plates are equipped with rollers on bearings, an electric motor with a gearbox. The transmission of motion is carried out through a cam-type clutch. In the steady rest, cartridges for pipes of various sizes can be changed.
Pipe bender "Azhur-6"
machine "Azhur-6"
The three-roll machine is designed for profile bending and rolled products along the radius, it works with pipes with a diameter of up to 80 mm, a strip of up to 100 mm, channels no larger than No. 12, an angle up to No. 63. Bending in horizontal and vertical planes is possible. The power of the electric motor is 1100 W, it operates from a three-phase power supply network 380 V. The rolls rotate at a speed of up to 11 meters per minute.
"Azhur-7" - the machine allows you to process hot metal. The machine is very convenient for forging for two reasons: 1 - unlike forging with a hammer, the machine is much quieter. 2 - we have a machine high speed and precision in the manufacture of identical parts. It is also worth noting that a person without special training can now do forging on a press, you can learn how to work on a machine in a few days. In fact, Azhur-7 will satisfy almost all the needs of production in blacksmithing. On it you can perform such elements of artistic forging as "forged ends", "peaks", "balusters" and much more.
The hydraulic forging press "Azhur-7" is unique in that it remains the only one of its kind in terms of price/capacity ratio. Those. this is the most best option for small and medium businesses. In addition, only proven Italian equipment is used in its nodes, the quality of the machine will delight you for many years.
In the place with the machine, you can also buy molds at a low price. We have a wide range of shapes for every taste.
When buying a machine, you will be pleased with a number of pleasant moments. Namely free shipping before transport company, 3 years warranty and services service center. Among other things, pay attention to our leasing program, if you do not have the entire amount at once, and production cannot reap, you can purchase a machine now - pay later.
