ForgingMachinesI AutomatedUpsetters

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Whethera standard forging machine for avariety of forging requirements,

or a tube upsetter for upsettinglarge diameter pipe, or

an automated forging machinefor high volume productionAjax Manufacturing Co.has the experience anddesign capability to meetyour production specs.

COVEA.' Rear axle f/at)ges are automatically producedat. the rate of 600pethOl.lt onAjSx.hign speed forgingmachines. $tcW:cJardotthe al1tomotive industry.

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TheAdvantages01ForgingwithanAJax

Ajax, the leader in modern forging machines,has pioneered in the design and manufacture offorging equipment since 1875. Ajax introducedthe first general purpose forging machine andcontinues its leadership by building advancedforging machines that maximize productivityand minimize part cost.

The Ajax line of equipment includes forgingmachines ranging from 2 to 10 inch capacityand tube upsetters in popular sizes. Forgingmachines can also be equipped with a varietyof transfer mechanisms to produce manyparts automatically.INCREASED PRODUCTIONAjax machines are designed for reliable serviceand maximum production. The Ajax-developeddirect-acting air clutch offers instant responseand smooth, cushioned starting at high operatingspeeds for maximum production rates. Accuratetorque regulation provides overload protectionduring heading.

The rigidity, power and precise alignment of theAjax extension-guided header and die slide helpproduce consistently accurate forgings thatrequire minimum secondary machining, furtherenhancing productivity. Metal displacementduring piercing is very accurate and concentric.Accurate header slide alignment holds tools con-centric in the die impression, reducing abrasionand wear when piloting is necessary.

Generous die height on 6 inch and larger sizesprovides space for additional forging operationsto make more intricate forged parts, and is par-ticularly advantageous on automated machinesin these sizes.

Approximately 60% of the headerslide stroke isnormally available for gathering stock. This canbe increased or decreased for special applica-tions at customer's discretion.

Production time is maximized because Ajaxmachine design keeps setup time to a minimum.Slip-tail clamps provide all the holding features

of studs without the need for lifting clampsduring die changes. Ajax machines can alsobe "inched" under power to save time andmanual effort.Ajax machines are convenient to operate, furthercontributing to productivity. Throat opening andoperating height provide easy access to the diesso the operator can stand in a balanced positionwithout interference from the tie rod. Forwardstock movement is also minimized.

DEPEN DABI LlTY AN D SERVICEABILITY

Ajax forging machines operate reliably andaccurately for extended periods, even underadverse conditions. Moving parts are protectedfrom scale and water by heavy steel shieldswhich have hinged doors for access to vitalareas where inspection and routine maintenancecan be made.

For routine maintenance and in the event serviceis required, all components are readily acces-sible. The exclusive Ajax underarm constructionmakes the pitman eccentric bearing easy toinspect and lubricate. The crankshaft can beremoved without disturbing the header slide andthe cam slide can be removed without disturbingthe header slide or crankshaft.

The flywheel, pinion shaft, clutch and brake arelocated above floor level in the frame extensionto the rear of the crankshaft housing. Clutchshaft bearings are capped so the shaft assemblycan be removed with minimum machine sideclearance.

All machine bearings are conservativelydesigned and made from carefully selectedmaterials to retain accuracy and assure longlife. A pressure lubricating system is standardequipment on 2 through 10 inch mac,~ines.Ajax forging machines are easy to maintainand can be completely disassembled in onlya little more space than they occupy. A flat,reinforced concrete slab with adequate area andthickness is all that is required for the foundation.

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BasicComponentsoJlheAjaxforging.achine

TOp.SUSPENDEDDIE SLIDEis outboard-guided for perfectalignment with the stationary die.A long fully backed shuttle plate supportsthe moving die under heading load.

HIGH MAINTOGGLEAND ALLOYSTEEL PINSprovide backingthroughout theentire die height.

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DIE CLOSING CAM

profile produces a large dieopening and keeps dies tightlyclosed during forging.

MULTIPLEOPERATION DIEScan upset or extrude hot orcold stock. Exceptionalmachine rigidity assuresprecise die alignment.

POWERFUL DIE GRIP

keeps dies closed under load without auxiliarymeans. A self-contained safety can throw outanywhere in the closing stroke to protect themachine and tooling.

FULLECCENTRIC CRANKSHAFTis standard on 3, 4 and 5 inchmachines. A two-piece full eccentric isoptional on 6 inch and larger.machines. Standard crankshafts canbe removed without disturbing theheader slide.

TOP-SUSPENDEDHEADER SLIDEis extension-guided to produceaccurate forgings under any loadconditions.

RIGID STEEL BED

is a one-piece steel casting with thick wall and heavyribbing. Continuous crankshaft bearing housings areintegrally cast to minimize crankshaft deflection.

V-BELT MOTOR DRIVE

is best for forging equipmentbecause it adapts to a variety ofmotors and transmits full motortorque.

AIR CLUTCHAND BAND BRAKEoffer fast, smooth starting andstopping. Conservative designassures long life and accuracy.

ALLOYSTEEL PITMANhas an exclusivenose bearing thattakes the forgingload and minimizesstress at the wrist pin.

MAIN AND PINION GEARSare alloy steel and have machinedteeth. Pinion shaft has anti-frictionbearings and the main gear is double-keyed to the crankshaft.

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RIGID STEEL

BedFrame- - -

Ajax forging machine bed frames are strain relieved,one-piece steel castings. Thick walls and heavyribbing withstand tremendous gripping and headingforces. The compact frame gets additional supportfrom heavy transverse ribs reinforced with a heavycross tie clamp. Two clamps are used on largermachines. The clamps provide crosswise rigidity forgripping stock and keeping dies tightly closed forproduction of flash-free forgings. They do notinterfere with machine operation.

Lengthwise rigidity is achieved with a heavy rib thatextends over the top of the crankshaft bearing and bya large-diameter longitudinal tie rod. Together theyreinforce the die slide, providing excellent die matchfor consistently accurate forgings.

Continuous crankshaft bearing housings areintegrally cast for minimum crankshaft deflection.Large diameter bronze bushed sleeves distributeloads developed during forging and reversal.Continuous bearing surfaces also provide anunbroken lubricating film that reduces wearand assures accurate, long-life service.

Cross tie clamp and large diameter longitudinal tie rod Continuous Crankshaft bearing housing

Main gear and pinion teeth aremachined from alloy steel andheat treated for strength andwear resistance.

CranksandDrivingGear

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The large diameter crankshaft is an alloy steel forging,heat treated for proper surface hardness and fatigueresistance. The full eccentric crankshaft (shown) isstandard on 3, 4 and 5 inch machines. The main gearis double-keyed to the crankshaft. Forged alloycrankshafts are standard on 2, 2-1/2, 6 inch and largerforging machines.

The exclusive Ajax underarm header slide constructionmakes it possible to disassemble and assemble thecrankshaft without removing the header slide andprovides easy access to the pitman bearing forinspection and lubrication.

The flywheel, pinion shaft, clutch and brake arelocated above floor level on the frame extension tothe rear of the crankshaft housing. No floor pits areneeded, and minimum floor space is wasted byoverhanging parts.

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EXTENSION.GUIDED

HeaderSlide

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The main header slide body carries the toolholder,pitman and wrist pin connection and is ruggedlyconstructed to prevent distortion from heading forces.Extension guide design improves forging accuracyregardless of load and underarm construction makesall major components visible and accessible.

Large bearing surface area keeps the header slide. accurately positioned even with the off-center loading

of multiple impression dies. Concentric, internallydisplaced and deep-pierced forgings are easilyproduced because heading tools precisely matchdie impressions.

Option toolholders are heldsecurely by a slot typestraddle clamp which

bears on the toolholdernear the ends of the slot. l

'" -Extension guide

maintains accurateslide position to insure

accurate forgingsregardless of load.

Wrist pin bushings areundercut at the front

surface so that the fullheading load is taken by

the pitman thrust bearing.

The header slide moves onhardened, ground steel lip liners

which extend the full length of .header slide travel to provideaccurate, reliable operation.

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Machine nose bearingsurface engagesheader slide,eliminating stressconcentrationsaround the wrist pin.

PitmanThe exclusive Ajax pitmandesign features a large nosethrust bearing which takes theheading load and minimizesstress on the wrist pin. Bushingsfor the wrist pin are undercut atthe front surface so that thethrust bearing takes the fullheading load. Alloy steelbearing cap bolts are used toovercome pull-off forces.

EXTENSION-GUIDED The header slide is extension-guided on all four sides in anunstressed portion of the bed frame where it is unaffected by

AT NEUTRAL forging loads. Cast iron extension guide liners assure accurateFRAME forging regardless of load conditionsand canbe truedand

POSITION shimmed without disturbing the header slide. The slide can beremoved without disassembling the crankshaft.

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The slide istop-suspended fromlong, wide alloy bronzefaced lips.

Shuttle support plate *

moves with the die slideto provide supportagainst the headingforce after the dies close.

* 3" and larger sizes

Rear view of thethe steel faced togglewhich prevents deflection.

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Standard equipmentslot tail die clamps neednot be lifted off the studswhen changing dies.

Ole SlideWITH SHUTTLESUPPORT PLATE

The outboard guide extensionkeeps the moving die in perfectalignment with the stationary die.

Strong underarm member connectsthe mam body of the die slide to theoutboardguide with virtuallyno deflection

shuttle support platethe moving die

The die slide is top-suspended and outboard-guided to maintain perfect alignment with thestationary die. Two long, wide lips operate on full-length hardened steel shelf liners to support theslide throughout its stroke. A rugged underarmjoins the main slide body and outboard guidebearing and is channeled to discharge forgingsand divert scale-laden cooling water fromoutboard bearing surfaces.

The outboard guide is completely framed withheavy ribbing in an unstressed portion of themachine bed. This die support system preventssagging and keeps the moving die parallel to thestationary die to produce consistently accurate,well-matched forgings.RIGID DIE SUPPORTThe Ajax-developed shuttle support plate keepsthe moving die from rocking under the headingload. Experienced users consider this featurethe greatest forging equipment improvementsince the air clutch. The long shuttle support

plate is attached to the die slide at the extremeleft end which allows longitudinal breathing. Theshuttle support plate is backed up with bronzeliners on the bed for its entire area.

FAST, EASY DIE CHANGESSlot-tail clamps hold the stationary and movingdies securely in place but need not be liftedfrom the studs when changing dies. Die heighton 6 inch and larger machines provides room formore die impressions, and together with the Ajaxfast-acting clutch, make it possible to forge inmultiple impression dies in one heat.

Die slide alignment is convenient. The heavysteel backing plate on the frame behind theshuttle plate can be removed for truing with theslide in place. The opposite side of the die slideis faced with a bronze liner which can be easilyshimmed to restore proper slide fit. Four castiron outboard guide plates can be shimmed toprovide proper running clearance with the slidein place.

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DieGriPWITH AUTOMATICSAFETY

Cam slide is a rugged steelcasting. It is designed tohave considerable strengthon pull-back.

Springs in the cam slideare mounted onsupport rods at both endsfor safety

Self-contained safety willthrow out from full dieopening and resetautomatically.

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The cam-actuated die grip mechanismis rugged and provides effectivegripping without auxiliary mechanisms.The cam profile imparts a smooth dieslide motion during opening andclosing and an accurate, circular camdwell keeps dies tightly closed duringheading. A return roller spring main-tains contact between the accuratelymachined cast alloy cam and theforged steel rollers. Cam and rollersare case hardened for long life.In the event of misplaced stock or otherobstructions, the self-contained safetymechanism will throw out anywhere inits entire closing stroke, actuating alimit switch that stops the machine.Inching procedure is used to reset themechanism on the header slide returnstroke.

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Cast alloy steelcam is machinedand hardened. Its

profile produces alarge die opening

and smooth motionduring die opemng

and closing.

Cam slide is supported in guidesboth forward and rear of the

crankshaft which it spans with atriple bndge. It can be easily

removed without disturbing theheader slide or crankshaft.

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HighMainToggleWITH MIDDLESUPPORTEDPINS

The safety mechanismon the cam slide is aspring loaded togglearrangement which iscontained within the camslide and is designed totrip at a force valuedetermined by the dieslide position. Togglegeometry and springrates are tailored foreach size machine toproduce the proper throwout characteristics.

BED FRAMEPIN DIE CLOSING CAM

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Ajax main toggleswithstand thetremendous loads developed inclosing and holdingdies closed.Large diameter alloysteel pinsprovide backing throughout theentire die height. Allpins haveliberal end-support surfaces to -prevent rotation or working downduring service. All bearings areindividually and automaticallylubricated and protected fromscale and water by heavy steelshields.

The die grip on Ajax forgingmachines is so powerful that itcan be used for limited shearing,punching, swaging, slitting andforging operations betweenthe dies.

Hard alloy steel maintoggle pin middlesupported in the bed frame.

PATENTED DIRECT-ACTING

AirClutchAND HEAVY DUTY

Brake

The direct-acting air clutch, first introduced onAjax forging machines in the early 1930's, isone of the most important developments inupsetter history. Instantaneous response andsmooth, cushioned starting at high speedsmakes it possible to perform more forgingoperations in one heat.The Ajax air clutch acts as a safety to protectagainst overload as well. With recommendedair pressure, torque capacity is controlled sothat the clutch will slip if an overload occurs.

An integral ventilation system and lowoperating pressure keeps clutch temperaturelow, extending friction material life. Ruggedconstruction includes low intertia steel drivenplates faced with non-metallic, wear-resistantfriction material. Clutch plates are easilyremoved.

The conservatively rated hinged-type bandbrake is spring set and air cylinder released.The brake drum is a score-resistant alloy steelcasting. A separate brake for stopping theflywheel is provided.

Specilications1" 1% " 21/2"2"

Floor Space

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V-BELT

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A short center, multiple V-belt motor driveis used on Ajax forging machines. Thisdrive system is best for forging equipmentbecause it transmits full motor torqueand provides a cushion necessary foroptimum performance.

Electrical control by a series of relayspermits three modes of operation:SINGLE STROKE, CONTINUOUS, andINCH. The three-mode capabilityincreases production versatility andminimizes setup time.

A squirrel cage motor is used on mostmachines. A punch press type motor withfive to eight percent slip is recommendedfor high speed operation on largermachines. A reversible motor isrecommended for inching purposes.

3" 5" 7" g" 10"4" 6"

20'4"x 13' 4"

25' 26' 9"x 14'8" x 17' 11"

23'9"x 14' 7"

Motor/900 rpm 15HP 20 HP

Strokes per min. :!:60 :!: 55

Weight/Pounds 39.000 50.000

. Molor R PM 720 or 750

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30HP 40 HP 125 HP 150 H.P. 200 H.P.

:!: 45 :!: 25 :!: 20:!: 23:!: 35

377.,000 500.000 735.00093.000 151.000 205.000

8' 10'8" 11' 6" 14'5" 16' 1"x 6'6" x7' x 7' 7" x 9' x 10' 2" x

Automation

The inherent accuracy and reliability of Ajax forgingmachines make them ideal for automation. Whenproduction volume warrants, Ajax forging machinescan be fitted with a variety of transfer mechanisms thatmake forging production completely automatic.With the cost of forging labor and materials on the rise,automation is one way to boost productivity and profit. Anautomated Ajax forging machine is the best way to do it.

Ajax automation engineers are ready to custom-designan automation system for your specific application.

Ajax Service is there,too, to back it withinstallation follow-up.

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Control

Ajax forging machines have all the standardequipment needed for most applications,and are designed to accept a variety ofinstrumentation and control systems.The need to monitor machine functionsincreases with production speed, and Ajaxforging machines can be supplied withsystems to put this information at theoperator's disposal. The Ajax engineering staffcan design a system to monitor and displaymain bearing temperature, flywheel speed,motor current and power, or stresses in thepitman, frame and die closing mechanism.Lube system operation can even be monitoredand in the event of a failure, can shut down themachine instantly.Instrumented machine functions can bedisplayed on a panel and used to signal theoperator of a fault, giving the machine a "selfdiagnosing" capability.

Automated 10" Forging Machine used in producingvan and light truck axle shafts with a capability ofproducing flanges up to 9" diameter at a rate ofapproximately 600 per hour. Total weight of machineis approx. 700,000Ibs. This 10" Forging Machine iscapable of exerting a 2500 ton heading force.

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For informationon Ajax TubeUpsetting Machines,send for BulletinNo. 93

-FORGING -FORGING -WIRE -FORGINGPRESSES ROLLS DRAWING MACHINES

EQUIPMENT

TheAJax. anullClurlng ComPIny1441 Chardon Road, NorthCleveland, Ohio 44117

Pnnted in USA