The old transformers were in an unsatisfactory technical condition and therefore there were frequent failures of the forging lines.
Extended lifetime of heaters at presses
Arguments for this investment included the high energy consumption and the risk of damaging the induction heaters. "Therefore, we have gradually replaced the transformers on both L-4000 lines, three L-1600 lines, and now we still have to replace them at the remaining two L-2500 lines", said Lukáš Andrášik, HKS Forge Technician. The most challenging part of this replacement, according to him, was the dismantling phase of two very unstable transformers, which had to be lifted to a height of four metres. "We were able to do this thanks to a tank device we rented from a company all the way from the Netherlands", added Lukáš Andrášik. These replacements will extend the life of the presses by another 30 to 40 years, he said. At the same time, the forge could save 5 to 10 thousand euros a month on electricity. HKS Forge invested 150 thousand euros in the replacement of all transformers.
New CNC equipment in the die shop
Innovation has also improved processes in the die shop, where forging tools are refurbished and produced. In addition to the current equipment, three lathes and two milling machines, the latest CNC machine, the Puma 5100, has been added. It is an efficient and precise horizontal four-axis lathe, which can also machine more demanding materials up to 400 mm in size. As Miroslav Jarcoliak, Die Shop Head, and Dávid Sanny, Technologist, say, the machine gives their team a wide range of options for tool restoration and production. They consider this innovation to be very important and believe that the classic lathes in the die shop will gradually be replaced by more modern milling machines.
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