Italy’s Danieli Group (Danieli Breda) recently commissioned a new integrated forging complex at the Zlatoust Metallurgical Plant (ZMZ) in Chelyabinsk region, Russia. The plant consists of a 25-MN open-die forging press and two integrated manipulators operating in conjunction with Danieli’s proprietary DanForge automation system. The open-die press has 80-spm frequency, a daylight span of nearly 11.5 feet, automatic top-die clamping and an automatic tool-changing device. The manipulators can lift ingots weighing 20 tons with a load moment of 60 t/m.
The DanForge open automation system provides complete coordination between press and manipulators to enable the highest productivity and repeatability of forging cycles. All activities for movement, management and control are accessible at the main desk, and only one person is needed to operate the complete forging line. The complex will allow ZMZ to produce high-quality forged parts with diameters of 4-32 inches (100-800 mm) and lengths of 33 feet (10 meters).