Case Study: Replacing Hydraulic Cylinders in 70-Year-Old Forging Press

Forging presses play an important role in the steel manufacturing process by helping shape material. Many steel manufacturers continue to rely on presses which are over 50 years old, and some that are as old as 100.

However, this has resulted in some challenges for machine owners when it comes time to replace or repair components. Often times, the original equipment manufacturers (OEMs) for these older presses are no longer in operation, leaving a significant gap in the market because it can be difficult to get parts when a forging press requires updates, repairs and replacements.

This is especially true for the huge hydraulic cylinders that make up the body of the force for the press. These are specialist parts that are not held in stock anywhere and that need to be manufactured specifically for the forging press.

Apex Hydraulics — a provider of design, manufacturing and repair services for hydraulic systems — is one of the companies in the market utilizing its expertise to create these specialized cylinders so machine owners can keep their older forging presses in operation. This case study from Apex Hydraulics offers an example of how it achieved this for a client in the steel manufacturing industry.

Read the article "Huge hydraulic press goes to work in California" to learn more about the use of hydraulics in forging presses.

The Challenge

Apex Hydraulics was approached by a forging company located in the UK which runs a large open die forging press that is almost 70 years old. The press was originally built by renowned forging press manufacturers Fielding and Platt which is no longer in operation.

After decades of operating, the press’ main cylinder piston rod within its 3,000-tonne press cylinder was heavily scored and damaged, resulting in leakage and inefficiency.

The forging press had been there since before the current factory was built. The forging press machinery was so massive and heavy that buildings were demolished and built up again around it, leaving the press in place.

Dismantling the machinery fully for repairs was not an option, and finding a replacement rod was proving difficult.  

The Apex Solution

Apex Hydraulics was able to offer a full replacement cylinder rod for the forging company’s press, along with bronze bushing and the replacement seal kit. The original specifications were found, and so the old rod could continue in situ (i.e., in its original place) while the replacement was being manufactured.

The piston rod Apex Hydraulics produced for the forging company measured 44 in. D x 116 in. L, and weighed 23 tonnes. It was manufactured from forged mild steel. 

For extreme durability it was induction surface hardened and hard chrome plated with a 50-micron chrome layer.