PICTURE OF THE YEAR #6: Ajax Forging Press Repair

PICTURE OF THE YEAR #6: Ajax Forging Press Repair

B.O.S. Field Machine in Houghton Lake, Michigan, deserves recognition for its outstanding work using a CLIMAX BB8100 Line Boring System to repair a massive 4,000-ton Ajax forging press. This press, located in Chicago, required repairs on both crank bores. The team utilized three support brackets to successfully complete the job, achieving an impressive 44-inch bore size.

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A 4,000-ton Ajax forging press is a heavy-duty machine used in the metal forging industry to shape large and complex metal components through immense pressure. It is commonly used in industries like aerospace, automotive, energy, and heavy machinery manufacturing. Here’s an explanation of its uses and why re-machining and line boring the crank bores are critical:

  1. Ensuring Proper Alignment
    • Problem: Over time, wear, thermal expansion, and mechanical stresses can cause misalignment in the crank bores.
    • Impact: Misalignment leads to uneven loading of the crankshaft and connecting components, increasing wear and reducing efficiency.
    • Solution: Line boring restores perfect alignment, ensuring smooth and efficient operation.
  1. Maintaining Dimensional Accuracy
    • Problem: Operational stresses can cause deformation or enlargement of the crank bores, deviating from OEM specifications.
    • Impact: Out-of-spec bores can lead to excessive vibration, improper bearing seating, and potential crankshaft damage.
    • Solution: Remachining ensures the bores are restored to their original dimensions, allowing components to function as designed.
  1. Extending Component Life
    • Problem: Uneven or damaged crank bores increase stress on the crankshaft, bearings, and other moving parts, accelerating wear and failure.
    • Solution: Precision re-machining reduces stress points and prolongs the life of critical components.
  1. Reducing Downtime and Repair Costs
    • Problem: Unaddressed wear or damage can lead to catastrophic failure of the press, resulting in significant downtime and expensive repairs.
    • Solution: Preventive maintenance through re-machining minimizes unplanned breakdowns, keeping operations running smoothly.
  1. Ensuring Operational Efficiency
    • Problem: Misaligned or worn crank bores reduce the press’s ability to apply force evenly, compromising forging precision and quality.
    • Solution: Remachining restores the press’s ability to deliver consistent force, ensuring high-quality output.
  1. Enhancing Safety
    • Problem: A press operating with damaged crank bores poses safety risks due to potential part failure under high loads.
    • Solution: Line boring and re-machining ensure the press operates safely and reliably.
  1. Compliance with Manufacturer Specifications
    • Problem: Deviation from OEM tolerances compromises the machine’s performance and may void warranties.
    • Solution: Remachining restores the crank bores to exact specifications, maintaining compliance.

Process of Remachining/Line Boring Crank Bores

  1. Inspection:
    • Assess wear, deformation, and alignment issues using precision measurement tools.
  2. Preparation:
    • Disassemble components as necessary and clean the crank bores for machining.
  3. Line Boring:
    • Use a portable line boring machine to achieve precise dimensions and alignment.
  4. Verification:
    • Check alignment, diameter, and surface finish with measurement tools to ensure accuracy.
  5. Reassembly:
    • Install components, recheck alignment, and perform test runs to verify functionality.

A 4,000-ton Ajax forging press is an essential machine for producing high-strength, precision-forged components. Re-machining and line boring the crank bores are critical to maintaining the press’s efficiency, reliability, and safety. These processes prevent costly breakdowns, extend the machine’s lifespan, and ensure the production of high-quality forged parts.  Congratulations to Beano Stearns for capturing this great application!