Machines for artistic forging openwork and master. Overview of machines for openwork cold forging

Today, an alternative to the classic forging of metal products in a furnace is cold stamping. The production of forged products by this method involves the use of special machines, among which the most popular are “Azhur”, artistic “Azhur 1M”, as well as “Azhur-Pipe Bender” and others.

Machine for twisting metal snails

Since the use of this equipment makes it possible to produce large volumes of products in a short time with minimal costs, it is necessary to consider in detail the process of using such machines and their varieties.

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:

1. 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.
2. To twist the rod, use the same machine with additional attachment equipment.
3. To screw the rings, add an additional nozzle.
4. 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 a different model range.

Manufacturer comparison table

We entered all the data obtained during our research into a small table. Criteria such as the quality of manufactured products and ease of use were assessed by blacksmith specialists. Our experts gave their verdict on issues important to a potential buyer: the price of equipment, additional services, ease of ordering and purchasing.

— lack of criterion; +/- incomplete match; + presence of criterion

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:

1. Power module for forging and drive mechanism.
2. Heating forge to maintain the temperature of the rods.
3. Forging module.
4. A drum fairing that is capable of cutting an annular opening with a diameter of no more than 110 mm.
5. The average cross-sectional size of a circle or square is 6-12 mm.
6. 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.
7. 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 promotion 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:

1. Modular accumulator injector.
2. Power plant compressor unit.
3. Two shafts on the bottom and top sides.
4. Strip guide mechanism.
5. Square roller slits.
6. 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:

1. Electrically driven motor.
2. Welded steel bearing part of the unit.
3. Gear reduction shaft.
4. Special module for forge straightening.
5. Part with electrical storage panel.

Video: Azhur 7 machine.

Guarantee

And the last criterion, important when purchasing any technically complex equipment, is the provision of warranty service for the machines:

• Manufacturers of forging machines of the “Master” and “Profi” series provide a 1-year warranty on all models.
• For Blacksmith, the warranty period depends on the dealer selling the equipment and can vary from 1 year to 3 years. There are a considerable number of dealers throughout the country, but machine service is located only in Moscow and St. Petersburg. Such a small location of service, given the wide distribution of machines, can cause inconvenience for blacksmiths living outside the territories of both capitals.
• Decor also offers a 3-year warranty period. However, in the case of this manufacturer, it is not entirely clear how the obligations will be fulfilled. Today it is impossible to contact the company.
• "Azhur" - provides a 3-year guarantee. At the same time, service centers are located in Chelyabinsk, as well as in most major cities of Russia, which provides the ability to quickly solve any problem with the equipment.

Thus, in terms of warranty obligations, “Azhur” is the undisputed leader.

3M

But for the production of more complex metal products, as a rule, a horizontal unit such as “Azhur-3M” is used.

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 has a high power level, no less than 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:

1. Stock grounding.
2. Hydraulic pump with gear base.
3. Hydraulic distributor with mechanical drive.
4. Hydraulic tank.
5. Oil filter.
6. 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.

Machines of the “Azhur” series are designed for artistic cold forging of metal. The cold forging method allows for many decorative details. Working on the machines of this line is safe, efficient and does not require special long-term training of personnel.

Ease of purchase

In addition to the availability of ready-made machines for sale from the manufacturer and the ability to purchase additional equipment, there are a number of other points that are especially important for beginners in the forging business. And these moments are connected with help in mastering a new business. At this point, we will simply list everything that machine tool manufacturers offer:

• The manufacturer has a service department that performs the following work: commissioning, warranty and post-warranty repairs, equipment diagnostics, production tests and technological consultations, supply of spare parts and equipment, instruction and training of personnel.
• The machines are endowed with a number of advantages: rich equipment in the basic configuration of the machines, high productivity and low cost of components and spare parts (20-50% cheaper than competitors).

• A wide range of equipment and tools allows us to equip the enterprise for the production of almost all types of decorative forged elements.
• Blacksmith machines and tools are adapted for working with Russian rolled metal. It is possible to process workpieces without preheating them, which increases productivity.
• The equipment is reliable and durable. Suitable for daily intensive use.
• All Blacksmith machines have an optimal combination of operating functions, which makes them easy to use and affordable.
• Ease of use allows even a beginner to master the operation of the machine in just 1 - 2 hours and produce high-quality serial products according to technological maps.

The company claims that it has a business plan, but it is difficult to find it in the public domain.

• The manufacturer offers both universal and specialized machines configured for a specific artistic forging operation (for example, only bending of various curls). This provides an opportunity for potential buyers to create a powerful production facility.
• The machines are configured to meet individual customer requirements.
• Free training on how to operate the equipment. Helps to master the equipment and share experience in working with metal.

(manufacturer of “Master” series machines)

• The manufacturer has a business plan, which contains: calculations of expected profit, description of machines and availability of products. Finding a business plan is not difficult, just go to the website and download it.
• Man offers business ideas that can help beginning blacksmiths decide on the direction of artistic forging.
• Using feedback from product buyers, it constantly modernizes manufactured equipment. Improves equipment modules and components, including at the request of clients;
• Based on his own experience, he gives advice on organizing the production of openwork products, technical issues, etc.
• Maintains connections with clients.

• The company provides a detailed business plan, which not only describes the features of the forge workshop, but also offers ready-made solutions for the selection of equipment and configuration, organization of the workspace and placement of machines. Provides calculations of expected profits depending on the purchased equipment.
• The manufacturer provides assistance in obtaining credit and leasing.
• If necessary, the company’s specialists are ready to go to the buyer to connect the equipment, perform commissioning and training on the capabilities of the equipment.
• In addition, Azhurstal provides free training for personnel at its own production for all its clients.

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.

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 the resulting serial products.

Openwork forging on a machine

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, let alone figurines.
• The limited shapes of the workpieces are rods, strips, and hollow bars.

The method is perfect for the production of small and medium-sized series of similar parts.

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 a 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.

Types of Azhurstal machines

Artistic forging machine "AZHUR-1M"

Azhurstal production machines are divided into several types:

• Universal bending machines for cold forging of 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 rod or profile, as well as to produce a twisted 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 steel and a machine for cross cutting of rolled metal.

Machine for artistic forging "Azhur-3M"

Azhurstal can, at the customer’s request, complete universal machines:

• portable forges for heating the ends of workpieces 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 the maximum size and complexity of manufactured elements.

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.

The basic package includes:

• 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.

Necessary materials

The list of materials used for cold forging includes

• The rod is round.
• Square bar.
• Pipes are round or square.
• Metal strip.
• Profiled rolled products.

In addition, you will need:

• grinder or cutting machine for cutting workpieces to size;
• welding machine;
• metalworking tools - vices, clamps, hammers, pliers, etc.

In a workshop or under a shed, you need to equip a spacious, flat place for assembling elements into a finished structure.

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.

Features of various machine models

Azhurstal offers a wide selection of equipment and additional accessories for all manufactured units.

The product line begins with the compact “Azhur-mini”. Despite its low power of 1.1 kW and modest dimensions, it can handle bars up to 16 mm. This is an excellent choice for a novice master.

The Azhur-1 station wagon has three times more power and a wider selection of additional equipment and accessories. It is designed for professional use and allows the production of up to 5,000 bent elements per month.

The rolling machine "Azhur-2" is designed for forming a three-dimensional pattern on strip, round and rectangular rolled products.

The universal “Azhur-universal” combines both a bending and rolling unit. This is already a small technological complex that allows you to significantly save working time.

In addition to them, “Azhur-4” is also supplied for producing twisted pipes with different pitches 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 of openwork forging.

“Azhur-1M” is a set of equipment designed for professional forging; the machine allows you to perform the basic elements of artistic forging.

By purchasing a machine, you will receive the following forging capabilities: — Smooth “foot” — “Foot” with a double-sided pattern — Forged ends No. 1,2,3,4 — Faceted peak — “Curl” and “volute” elements — Torsion bar “longitudinal twisting” — Volumetric “basket”, as well as ring arcs of various angles and diameters.

So you can purchase at a low price additional equipment for the Azhur-1m artistic forging machine, expanding its capabilities and simplifying its work. For example, an electromechanical drive, metal heating, a bending block (allowing metal to be bent within the required radius), rollers for bending a profile, rollers for rolling a profile pipe and a device for tight curling. As well as CNC (computer numerical control), which will automate production and perform work with computer precision.

By purchasing an artistic forging machine "Azhur-1M" at the manufacturer's price, you will receive a reliable and unpretentious device, which, in addition to its low energy consumption, is highly productive, which is important in production, because high productivity will quickly recoup the investment and you will achieve absolute profit.

When purchasing a machine, we are pleased to offer you an additional range of services for your comfort, for example, we will deliver the purchased machine to the Transport Company. We provide a 3-year warranty on the machine. We have a customer service where our specialists will help you resolve any issues. We can also offer you a machine for leasing, i.e. you don’t have to save or borrow money for a machine, you buy a machine, start working and pay for the machine.

In order to effectively cold forge metal, the latest machines from the “Azhur” series universal are used. By cold metal processing you can make many products with decorative patterns. Machines of this type are safe to use, highly efficient, and there is no need to attract qualified personnel.

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.