Industrial Forging and Extrusion

With an understanding that the industrial forging and extrusion industry relies heavily on decades-old equipment, System Seals has redesigned the stock rubber V-packing used for forging equipment and developed a custom sealing solution with more than twice the normal lifespan.

System Seals’ proprietary Elite system integrates at least one polyurethane seal in conjunction with the traditional rubber-and-cloth seals that run up to 2100 millimeters in diameter. The combination maximizes the sealing abilities of rubber while increasing the abrasion resistance of polyurethane.

Because each heavy-duty press differs greatly, System Seals custom designs blended-material V-packing for every ram. System Seals specialists analyze previously worn seals to identify weaknesses and then examine the design, condition, and intricacies of the ram itself to recreate an entirely new V-packing.

Custom-designed products for heavy-duty presses in the forging and extrusion industry from System Seals are often produced and delivered considerably more quickly than off-the-shelf replacements. And because lost productivity can run into the millions, System Seals can help with the installation and any technical support long after the sale, including any future maintenance and repair concerns.

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System Seals’ custom-designed products for heavy-duty forging presses include sealing solutions for:

• Main Rams
• Side/Pullback Cylinders
• Manipulators
• Plunger Pump Packing
• High-Pressure Flanges

For aluminum extrusion presses, System Seals offers uniquely designed solutions for:

• Main Rams
• Container Cylinders
• Shear Cylinders
• Side/Pullback Cylinders
• Die Slide Cylinders
• Tie Rod Bushings

Also, for automotive and tire presses, System Seals develops custom seals for:

• Side/Pullback Cylinders
• High Pressure Flange Seals
• Center Mechanisms
• Pot Heaters
• Cold Forming Presses
• Press Brake

Additionally, System Seals is equipped to develop a range of sealing solutions for:

• Bailing Presses
• Chipboard and Veneer Presses
• Scrap Sheers
• Ceramic and Brick Presses

Extrusion Process

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. The extrusion process can be used with plastics, metals, ceramics, and other materials.

The advantages of extrusion over other manufacturing processes include:

• Extrusion can be used to produce complex shapes that would be difficult or impossible to produce using other methods
• The extrusion process is relatively quick and efficient
• There is little waste generated during extrusion
• Extruded products have a consistent cross-sectional shape throughout their length

Applications for extrusion include:

• Creating pipes and tubing
• Producing rod and bar stock
• Manufacturing profiles and shapes
• Making extruded coatings and films
• Forming extruded sealants and adhesives

The extrusion process can be divided into two main steps:

1. The material is fed into the extruder barrel, where it is heated to the proper extrusion temperature.
2. The softened material is then pushed through the die by a screw or plunger, taking on the shape of the die opening as it exits the extruder.

There are many different types of extrusion processes, each suited to different materials and applications. Some of the most common extrusion methods include:

• Direct extrusion – The direct extrusion method involves forcing material through a die using a tool or ram to form it into the desired shape. This process is typically used for metals such as aluminum and steel that can be easily deformed under pressure.
• Forward extrusion – The forward extrusion method utilizes an inclined die to pull the material through while applying pressure from behind. This method is commonly used to produce large metal objects such as pipes and tubes.
• Rotary extrusion – Rotary extrusion uses a rotating die to shape the material as it is pulled through. This process is often used for plastics and composites that may be difficult to deform using other methods.
• Roll forming extrusion – Roll forming extrusion involves passing the material through a series of rollers to shape it into the desired shape.
• Hydrostatic extrusion – Hydrostatic extrusion uses fluid pressure to push the material through the die, making it ideal for fragile materials that could be damaged by traditional extrusion methods.
• Ram extrusion – Ram extrusion utilizes a hydraulic ram to force the material through the die. This method is often used for larger objects that require high levels of force to deform them.
• Cold extrusion – Cold extrusion is an extrusion process that takes place at low temperatures, below the material’s recrystallization temperature. This method is often used for metals that are difficult to deform at high temperatures.
• Hot extrusion – Hot extrusion is an extrusion process that takes place at high temperatures, above the material’s recrystallization temperature. This method is often used for metals that are easier to deform at high temperatures.

Overall, while there may be more than one extrusion method, the extrusion process is a versatile technique for creating products with complex shapes and precise dimensions. Whether you need tubing, rod stock, or another type of product, extrusion can be a cost-effective solution for your manufacturing needs. With System Seals manufacturing process and strategic mechanical methods, we can tackle nearly all of your extrusion needs.

Metal Forming Process

Metal forming is a group of manufacturing processes that alter the shape and size of metal parts, often to extreme amounts. There are many different kinds of metal forming processes, each with its own applications. However, they all share one thing in common: they change the shape or dimensions of an object by compression, deformation, or rupture.

Some common examples of metal forming include forging, extrusion, and cold rolling. Forging is a process in which hot metal is shaped into solid objects using large presses or hammers. Extrusion involves forcing a pliable piece of metal through a die to create long, thin products such as pipes or tubes. And cold rolling is used when only small changes need to be made to the shape or dimensions of an object.

There are many advantages to using metal forming processes. They can be used to create parts with very precise dimensions, and they can be used to create parts with very complex shapes. Metal forming processes are also relatively fast and efficient, and they often require less energy than other manufacturing processes.

There are some disadvantages to metal forming as well. One is that it is difficult to produce parts with very thin walls using metal forming processes. Another is that the process can sometimes introduce imperfections into the metal, such as wrinkles or cracks. Finally, metal forming processes usually require expensive equipment, which can make them prohibitively expensive for small-scale production.

What are different types of Forging Methods?

While there are many types of forging processes, every company may be different in their forging options.

• Impression Die Forging – Impression die forging is a type of hot forging in which metal is shaped by pressing it into a die. The die is usually made of steel, and the metal being forged is heated until it is malleable. Once the metal is hot enough, it is placed in the die and pounded or pressed into the desired shape.
• Open Die Forging – Open die forging is a type of hot forging in which metal is shaped by hammering or pressing it while it is hot. The metal being forged does not need to be placed in a die, as the shape can be created by using various tools.
• Closed Die Forging – Closed die forging is a type of hot forging in which metal is shaped by pressing it into a die. The die is usually made of steel, and the metal being forged is heated until it is malleable. Once the metal is hot enough, it is placed in the die and pounded or pressed into the desired shape.
• Metal Forging – Metal forging is a process in which metal is shaped by hammering, pressing, or rolling. Forging can be done with hot metal or cold metal. Hot forging is usually done with steel, and the metal is heated until it is malleable. Cold forging is usually done with aluminum, and the metal does not need to be heated first.
• Cold Forging – Cold forging is a type of forging in which metal is shaped by hammering or pressing it while it is cold. The metal being forged does not need to be heated first, as the shape can be created by using various tools.

System Seals has developed customized seals for all of the industry’s leading presses, including:

• Mesta
• Verson
• Clearing
• Siemplekamp
• Erie
• United
• UBE
• Presezzi
• Loewy
• Sack
• Watson Stillman
• Wean United
• SMS
• Pahnke
• Muller Weingarten

Tim Batten

With nearly two decades in the seal industry, Tim Batten has worked with the largest forging and extrusion plants in the nation, helping to optimize equipment performance and reliability.