The manufacturing process and precautions for hydraulic presses
Clearly define the purpose of the press (e.g., metal forming/waste compression) and calculate the load requirements to determine the hydraulic system working pressure (≥10 MPa) and stroke parameters.
Release Time：
2025-05-30
Hydraulic Press Production Process and Precautions
I. Production Process
Design Planning
Clarify the press's purpose (e.g., metal forming/waste compression) and calculate the load requirements. Determine the hydraulic system working pressure (≥10MPa) and stroke parameters.
Draw the machine body structural diagram: including the upper beam, columns, slider, and hydraulic cylinder positioning holes, etc. The columns need to reserve a threaded locking structure.
Material Preparation
Machine body material: Select Q235 steel plate (thickness ≥15mm) or channel steel. The columns use 45# quenched and tempered steel (hard chrome-plated surface).
Hydraulic system: Includes hydraulic cylinder (U-shaped imported seals), solenoid valve group, high-pressure oil pipe (pressure resistance ≥25MPa).
Machine Body Welding and Assembly
After CNC cutting of the steel plates, they are welded together. The weld height is ≥8mm, and stress relief is performed after welding at 600℃.
CNC boring and milling machine processes the slider guide holes. The hole diameter tolerance is controlled at H7 level (±0.018mm).
Hydraulic System Assembly
The hydraulic cylinder is connected to the upper beam flange, and the piston rod end is hinged to the slider (mating tolerance H8/f7).
Before installing the oil circuit, the hydraulic oil needs to be filtered using a 20μm filter element. Apply sealant to the pipe joints to prevent leakage.
Control System Integration
Configure the PLC control module and set the pressurization/pressure holding/pressure relief program (pressure holding time is adjustable 0-60 seconds).
Install a pressure sensor to monitor the system pressure in real-time. The automatic alarm threshold for overpressure is set to 110% of the rated value.
Debugging and Testing
No-load operation: The hydraulic cylinder reciprocates 10 times at full stroke, and the slider parallelism is checked (error ≤0.1mm/m).
Load test: Step-by-step pressurization to the rated pressure, and check the hydraulic cylinder for leakage after holding pressure for 5 minutes.
II. Key Precautions
Safe Operation Specifications
Before pressurizing, confirm that the workpiece is firmly fixed. Do not pressurize suspended or inclined workpieces.
During debugging, operators must wear anti-smashing shoes and goggles. The hydraulic system pressure measurement point needs to be equipped with a burst valve.
Material and Process Control
The welding area needs 100% flaw detection. Cracks or pores need to be ground and re-welded.
The column thread accuracy is not lower than 6g grade, and the pre-tightening force of the locking nut needs to reach 70% of the yield strength.
System Calibration and Maintenance
Change the hydraulic oil and clean the oil tank every 500 hours. Replace the filter element immediately if the pressure difference exceeds 0.3MPa.
Check the pressure sensor accuracy monthly. If the deviation exceeds ±1.5%, it needs to be recalibrated.
Special Condition Response
In high-temperature environments, add an oil cooler to keep the oil temperature ≤60℃ (oil viscosity not less than 46cSt).
For frequent start-stop conditions, it is recommended to use a variable displacement piston pump to reduce energy consumption by more than 30%.
Typical Application Data:
A 10-ton small press weighs about 800kg, and the motor power is 7.5kW.
The pressure for waste metal compression and forming needs to reach 15-20MPa, and the compression ratio can reach 1:5.
(Production cycle: Standard presses take about 15-20 working days from design to delivery).
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