To write an article about new products in forging equipment I was inspired by chance. I recently ordered a window grille from a workshop. Word by word, I got into a conversation with the blacksmith, a young man of about thirty, Alexei Baryshnikov. At first the conversation turned to small business, and then quietly turned to technical topics.
“For the time being, in our workshop we specialized mainly in welding and cutting metal - circles, corners, squares,” said the blacksmith, “but there were not enough forged elements. So the clients went to their neighbors who had a hammer. Recently we also took an old 75 hammer. They completely put it in order, removed the gaps, and installed the taps according to the passport. But you still have to work the pedal extremely carefully and constantly focus on the firing pin. You will make a mistake from fatigue, you will not follow, and instead of lightly hitting the workpiece, you will strike such a blow that the almost finished part is flattened. The guys say it’s all because I’m not an experienced blacksmith. Isn’t there really a normal hammer that would independently regulate the amplitude of the striker?”
To be honest, this problem surprised me. And in fact, doesn’t our industry produce 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 use it?
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A Yandex search led me to the plant’s 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 produce many elements that, as a rule, are made with a hammer,” said the commercial director. - But you need to have a lot of experience working with a hammer. Whereas our press can be operated by a person who has never worked before artistic forging, no special clearances or ranks are required for work. A person can learn how to operate a machine in 2-3 days. Also, we must not forget that this equipment is designed to produce identical elements in large quantities. The elements can be used both in the production of your own forging, and sold individually.”
Apparently, this was exactly what I was looking for for Alexey Baryshnikov.
- Tell me, Oleg, exactly what parts can be produced at Azhur-7?
Regarding artistic forging manually by 90%, depending on the use of standard molds or those custom-made by the buyer of the equipment, the execution of the element is limited only by the maximum stroke of the slider of 210 mm and the size of the mold, approximately 200 * 50 mm.
In other words, Azhur-7 covers almost all the needs of blacksmiths from private workshops. How reliable is Azhur-7? What components and mechanisms make the machine original and durable?
Our company has long specialized in the production of high-speed hydraulic presses; now the line includes three hydraulic presses: 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 equipped with foot pedals.
Is there a guarantee? What forms of service (ease of repair and availability of spare parts) does your company offer? After all, it happens that a machine breaks down, and you have to wait months for spare parts.
12 month warranty. Our company has created a department technical support operation, commissioning, warranty and post-warranty service. The engineers of this department will not only provide 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 manufactured at our factory and are always available in stock, you don’t have to wait for months for them, which cannot be said about 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, who make many elements by hand or with a hammer, but this takes a lot of time. This is the first press designed specifically to perform such elements of artistic forging and at the same time very affordable for small and medium-sized businesses - 410,000 rub., including a force of 100 Tf. There are no analogues as such, or we could not find information about them; no one produces them in Russia. There are presses that differ greatly in size or cost by several times; they, of course, can produce the same elements, but very few people can pay about 50,000 Euro for it.
Yes, the difference is significant. 410 thousand rubles is not such a large amount for a small business, in any case, it is reasonable, which cannot be said about two million rubles. How does it work? What makes it convenient for forging?
Well, firstly, the press is much quieter than when forging with a hammer, and secondly, it has great accuracy and speed of manufacturing identical elements. I repeat, our press can be operated by a person who has never worked before. artistic forging, no special clearances or ranks are required for work. A person can learn how to operate a machine in 2-3 days.
Small business does not tolerate downtime. Is it possible to say about Azhur-7: “I bought it, delivered it, installed it, turned it on and it’s working”? So this machine is without any headaches?
The machine leaves the factory gate absolutely ready for work; you just need to connect it to the electrical network and fill the hydraulic oil into the hydraulic tank.
Everything I learned from commercial director Azhurstal group of enterprises, told Alexey Baryshnikov. The blacksmith had already suffered a lot with the old hammer, so he accepted my information with a bang. And just recently I met Alexey again, who finally bought Azhur-7. The master shook my hand for a long time out of gratitude, repeating: “Excellent machine!”
“We, blacksmiths, do everything with our own hands and know how important it is to be in demand among our citizens,” said Alexey. - Therefore, buying Russian equipment, we vote for our country. And this is very important."
Alexander Sitnikov
Machines of the “Azhur” series are designed for artistic cold forging of metal. Method cold forging allows you to create many decorative details. Working 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 involves torsion and bending of rods of a certain cross-section. The result is a set of parts from which the finished product is assembled.
Specialized Azhur machines allow you to perform the following operations:
- bending elements according to a template using the rotation method. This procedure is performed using special templates compatible with the spindle. The role of the machine is to control the accuracy of the corners;
- the rod is twisted on a machine of the same type with additional attachments included in the package;
- winding of rings is carried out on a special nozzle;
- cutting of forged parts is carried out on a special type of machine - scissor. The parts of the part are shifted relative to each other, creating an even, neat cut.
Now let’s learn more about the “Azhur” machine of each model.
Bending machine "Azhur-1M"
machine "Azhur-1M"
It can produce almost any popular elements used in artistic forging products:
- baskets;
- volutes;
- rings;
- peaks;
- reverse folds;
- endings;
- torsion bars;
- snails
The power of the machine is 3000 W, it operates from 220 or 380 V networks. “Azhur-1M” works with workpieces with a diameter of 8 to 16 mm, profile pipes No. 15 and No. 20. Torsion bars are made from 10 - 20 mm rod. The working shafts rotate at a speed of 7.5 revolutions per minute.
Additionally, the Azhur machine is equipped with:
- a power unit that drives the forging module;
- forge for heating the ends of the rod;
- forging module with a set of eccentric rollers. With its help, the ends of the rods “crow’s foot”, “faceted peak”, “dome peak” and others are formed;
- a drum for making a “ring” part with a diameter of 114 mm from a rod of round or square cross-section from 6 to 12 mm;
- snail - used to make curled elements from profile pipe, round or square rod. Completely eliminates the appearance of creases;
- torsion bar - 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 forge. Mechanical elements:
- electric motor;
- bed;
- forging module;
- gearbox;
- equipment
An electric motor drives the lower roller of the forging module through a gearbox. 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 forge is powered by a gas burner.
Rolling machine "Azhur-2"
machine "Azhur-2
The purpose of "Azhura-2" is to apply a convex ornament to a profile pipe, strip, square and round rod. The power of the electric motor is 3000 W, it operates from a three-phase network of 380 V, modification for 220 V is possible. The equipment rolls up to 4.5 linear meters per minute.
Maximum cross-sectional size of the workpiece, in mm:
- profile pipe 40 x 40;
- stripes 20 x 20;
- round bar diameter 20;
- side of the square is 20.
The shafts rotate at speeds of up to 7.5 revolutions per minute. There are two configurations of the machine: basic and complete.
IN basic equipment included:
- forging module;
- power unit;
- upper and lower shafts;
- gear cage with adjustment - necessary for simultaneous rotation of both shafts at any position of the upper one;
- strip guide;
- guide mechanism for square;
- rollers for rolling cuts in the shape of a square;
- rolling textured rollers;
- "Greek" ornament for stripe.
The complete package additionally includes:
- 37 types of rolling reliefs;
- 7 sets of shafts for rolling different reliefs onto a profile pipe, square;
- horizontal straightening mechanism;
- smooth adjustment of rolling speed.
The rolling machine "Azhur" consists of the following elements:
- electric motor;
- welded steel frame;
- gearbox with gears;
- forging module with a straightening mechanism;
- electrical part
The motor, through a gearbox with gears, supplies rotational motion to the shafts of the forging module. Forming rollers are located here. The rod passes between the upper and lower rollers and takes on the shape of the rollers. After which the part is fed to a straightening mechanism: two balancers, which give the part a flat or curved shape.
Rolling and bending machine "Azhur-Universal"
machine "Azhur-Universal"
This model is a combination of two previous machines “Azhur-1M” and “Azhur-2”, which allows you to create almost all known forging elements, process edges, and roll ornaments onto parts of different profiles.
The machine is offered in two configurations: basic and complete. It works with workpieces 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 operating from a three-phase 380 V network. The machine is designed to work in small and medium-scale production.
Mechanical elements of the rolling-bending device "Azhur-Universal":
- electric motor;
- bed;
- two forging modules;
- gearbox;
- electrical part
By means of a belt drive, the electric motor transmits movement to the gearbox and rollers of both forging modules. Eccentrics are located on the middle and lower rollers of the first forging module; they make parts in the shape of a “spade”, “peak”, “crow’s foot”. A “snail” is attached to the outer part of the middle roller. Using a combination of the console and the top roller, “torsion bars” are performed.
Horizontal press "Azhur-3M"
hydraulic press "Azhur-3M"
The hydraulic horizontal press "Azhur-3M" is designed for the production of metal fences, bars made of rods with a diameter of up to 20 mm, and strips with a width of up to 20 mm. Designed for use in large-scale production.
Electric motor power is 5500 W, rotation speed is 1450 rpm. Operates from a three-phase 380 V network. The press creates a force of 30 tons. It comes with equipment for making patterns: “wave”, “cartouche”, “angle”, “semicircle”, “French profile”, “eshka”, “chervonka” and others.
The press consists of the main elements:
- base;
- gear hydraulic pump in tandem;
- electromechanical hydraulic valve equipped with a safety valve;
- hydraulic tank;
- hydraulic cylinder;
- stamp with column guides;
- oil filter;
- electrical panel
Machine oil 403 and Shell Tellus 46 are used as the working fluid. The pump unit is protected from overloads by a safety valve. The press is installed on a hard surface of asphalt or concrete and adjusted horizontally according to the level.
Machine for twisted pipe "Azhur-4"
machine "Azhur-4"
This machine can produce twisted pipes with a diameter of 10 - 160 mm, with a given coil angle. This element greatly decorates the finished product and is used as a stand for a lantern, furniture, or 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 rotation speed of the shafts is 18 revolutions per minute.
On the base there is a support plate with grooves (3 pieces) located at an angle. Sliders (3 pieces) equipped with movable brackets are attached to the base plate. On the back surface of the plate there are rulers to control movement. Each bracket is equipped with rotating plates, which rotate along their axes relative to the bracket. You can set the position of the plate using the lock.
The rotary plates are equipped with rollers on bearings and an electric motor with a gearbox. The transmission of motion is carried out through a cam-type clutch. The steady rest allows you to change cartridges for pipes of different sizes.
Pipe bending machine "Azhur-6"
machine "Azhur-6"
The three-roll machine is designed for bending profiles and rolling along a radius; it works with pipes with a diameter of up to 80 mm, strips up to 100 mm, channels no larger than No. 12, angles 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 of 380 V. The rollers rotate at a speed of up to 11 meters per minute.
In order to effectively cold forge metal, the latest machines from the “Azhur” universal series are used. Cold metal processing can be used to make many products with decorative patterns. Machines of this type are safe to use, high efficiency, and there is no need to attract qualified personnel.
Advantages of cold forging using the Azhur machine
In this way, you can easily twist and bend rods of the required cross-section. This makes it possible to make parts of a certain type and, based on them, assemble a finished product.
Capabilities of openwork universal machines today:
- Bend elements by rotation strictly according to specified parameters. Most often combined with a spindle. A modern forging and universal openwork machine is capable of controlling angular inclination with high precision.
- To twist the rod, use the same machine with additional attachment equipment.
- To screw the rings, add an additional nozzle.
- All forged parts are cut on a scissor unit. All side faces of the mechanism are made offset with respect to the rubbing surfaces. Thus, the cut is smooth and thoughtful.
Currently, “Azhur” forging machines are produced with different model range.
For metal bending
As a rule, the brand is Azhur M-1. It produces the following items:
- basket nets;
- ring mixers;
- bends in the opposite direction;
- volute and torsion seals.
The minimum power of the unit is at least 3000 W. Capable of operating from a 220-380 V network, while the size of the processed workpieces is 8-16 mm. The width of torsion bars is at least 15-20 mm. The speed of the working shaft is no more than eight revolutions per minute.
Additional elements for completing the Openwork unit:
- Power module for forging and drive mechanism.
- Heating forge to maintain the temperature of the rods.
- Forging module.
- A drum fairing that is capable of cutting an annular opening with a diameter of no more than 110 mm.
- The average cross-sectional size of a circle or square is 6-12 mm.
- When processing a profile pipe, a snail is made. The cross-section of the rods is made in the shape of a square and a circle.
- The torsion element is compatible with specialized washer and transition torques.
The mechanism works perfectly using electrical parts, mechanics, and the forge frame. Main functional mechanisms:
- motor on electric drive shaft;
- base of the case mechanism;
- forge spinning module;
- synchronous gear fairing;
- equipment with a mechanical element.
The gear shaft drives the base of the forging fairing. This is how the upper and lower order rollers are affected. The workpiece is bent into any shape during the movement of special eccentrics. But first, the workpiece must be heated to its melting temperature.
Openwork 2
To make a convex exit to the surface of the pipe, use the Azhur 2 machine. It is also ideal for strip rods, as well as in the shape of a square. The engine gains power up to 3000 W, is capable of operating from a 380 V mains phase, and can be modified to 220 V.
The average output per minute is up to 4.5 meters, while the shaft speed is approximately 7.5 revolutions over the same period of time. Modern machines consist of units of the main series and a complete set.
Main series mechanisms:
- Modular accumulator injector.
- Power plant compressor unit.
- Two shafts on the bottom and top sides.
- Strip guide mechanism.
- Square roller slits.
- Decoration of stripes according to the Greek method.
Complete mechanisms that are installed on the Azhur 2 machine:
- 37 varieties with relief knurling;
- 7 varieties for profile square pipe;
- device for horizontal straightening;
- a unit that monitors changes in the speed of a rolling element.
Currently, the most modern Azhur machines, as well as universal rolling machines, include many simple and complex elements, such as:
- Electrically driven motor.
- Welded steel bearing part of the unit.
- Gear reduction shaft.
- Special module for forge straightening.
- Part with electrical storage panel.
Video: Azhur 7 machine.
3M
But for production more complex products As a rule, a horizontal unit such as “Azhur-3M” is used from metal.
Using this machine you can do:
- metal fencing;
- twig gratings with a diameter of up to 20 mm;
- strip elements with a width of at least 15-20 mm.
The electric motor is different high level power of at least 5500 W, with a torque frequency of 1450 rpm. It operates exclusively from a 380 V network. The press force is very high - at least 30 tons and is characterized by a high level of reliability.
Components of the device:
- Stock grounding.
- Hydraulic pump with gear base.
- Hydraulic distributor with mechanical drive.
- Hydraulic tank.
- Oil filter.
- Electrical platform.
Most often, oil for 403 machines under the Shell Tellus 46 brand is used to ensure operation. A special protection valve protects the mechanism from overloads during operation. The press of a forging machine is installed on a hard, stationary surface, usually asphalt and concrete. All work is carried out strictly according to the instructions.
