Special tools for a shipyard, this is the last major work done by METALMAQ, a great specialist in large tools with guaranteed operability.
OUR CUSTOMER’S NEEDS
Our customer is a shipyard in the south of Spain, one of the most recognized worldwide and has recently purchased a new 1000-tonne, 6-metre long ERMAKSAN press brake.
This is a regular customer, and about two years ago we manufactured a whole set of punches for their old LOIRE press brake, which is still in operation.
Now with their new acquisition they want the same punches that were manufactured, but adapted to the new clamping and also a special, large-sized die 6 metres long, all in one piece.
THE PUNCHES
New 1000-tonne, 6-metre long ERMAKSAN press brake has the Promecam (or European system) clamping on the punches, which is one of the most widely used worldwide.
They want two types of punches, one with a bit of “claw” to make a U shape, with a height of 125 m/m, a radius at the tip of 2 m/m and manufactured in induction-hardened, ground 42CrMo4 steel.
This first punch is manufactured in 9 metre lengths, but in fractioned lengths according to our customer’s criteria.
The second punch is straight, robust and full-bodied, with a height of 125 m/m, a radius of 10 m/m and is suitable for bending sheet thicknesses up to 25 m/m.
For this reason it is also made of induction-hardened, ground 42CrMo4 steel. The length is also 9 metres in total, divided into measurements our customer requested.
At the top you can see the 2 special punches, with the shapes described above and with the Promecam clamping.
Special tools for a shipyard. The weight of these two punch assemblies exceeded 700 kg. The following photographs show how they were packed and shipped to their destination, ready to be used in the construction of naval vessels.
THE DIE
The die the customer requested was very large, with a “body” size of 240 x 240 m/m and 6 metres long, in one piece.
It was equipped with 6 V shapes distributed on its 4 sides, according to our customer’s design, with the largest V shape being 180 m/m, prepared to fold sheets up to 25 m/m thick.
To ensure a long service life without premature wear, it is made of induction-hardened, ground 42crMo4 steel.
In the first photo you can see the large size of the die (in the packaging process), and in the second photo its identification plate, with our logo, the manufacturing number (to ensure its traceability), and the design number of the die, in order to be able to identify it for possible future management.
One of the things that makes us unique in Europe is our own hardening facilities. This process is vital to ensure the service life of the punches and dies manufactured, but with such a large die (weighing more than 2,000 kg), the facilities must be up to handling such dimensions.
The following pictures show the hardening process of the special matrix in our facilities. Induction hardening is a guarantee of durability and success.
THE DIMENSION OF THE MANUFACTURED TOOLS
Two boxes were sent to our customer. The first box was 3 metres long and weighed 715 kg, and the second box was 6 metres long and weighed 2,150 kg. In total 2,865 kg of tools were sent!!!
