Refurbishing Old Presses for Modern Use

admin·September 11, 2024·0 comments

In the fast-paced world of manufacturing, technology is constantly evolving, leading many companies to upgrade their equipment with the latest advancements. As a result, older machines, such as presses, are often replaced and left to languish in storage yards or are eventually scrapped. However, at Dieffenbacher North America, we have found a way to breathe new life into these aging giants, ensuring they continue to serve their purpose effectively for years to come.

One particular success story involves a component of a multi-opening press frame known as the bottom crosshead. This vital piece supports the weight of the press and keeps it together during operations. Over decades of use, stress points can develop cracks, rendering the press inefficient or unsafe. Recently, we received a request to refurbish a bottom crosshead that had been decommissioned and left in a customer’s yard for over a decade.

The Refurbishing Journey

The journey of refurbishing an old press component begins with a thorough documentation of its arrival condition. Our first task is to identify any potential areas of concern, including previously manufactured defects that may not meet today’s modern standards or any cracks that have developed over time. However, the process is complicated by the presence of surface contaminants, which often hinder detailed inspection.

Step 1: Surface Preparation

To tackle these challenges, the component is subjected to sandblasting to remove all surface contaminants. This preparation is crucial for a thorough inspection and assessment of the component’s integrity.

Step 2: Non-Destructive Testing

After cleaning, we employ three types of Non-Destructive Testing (NDT) to ensure the structural integrity of the component:

  1. Visual Inspection: We meticulously examine the surface for any visible defects or cracks. This initial assessment helps identify obvious issues that require attention.
  2. Magnetic Particle Testing & Liquid Penetrant Testing: These advanced techniques are used to detect micro-cracks that may not be visible to the naked eye. They provide a detailed look at the surface condition, ensuring no defect goes unnoticed.
  3. Ultrasonic Testing: If cracks are found, ultrasonic testing is employed to detect cracks within the material. This method allows us to assess the internal structure without causing any damage to the component.

Step 3: Repair and Documentation

Once all defects are identified, the component undergoes a comprehensive repair process. Each repair is meticulously documented to maintain a record of the refurbishing process, ensuring transparency and accountability.

Step 4: Priming and Machining

Post-repair, the crosshead is primed before moving on to machining. This critical step protects the piece from rusting when coolant is applied during machining. Priming acts as a barrier, safeguarding the component against environmental factors that might compromise its durability.

Step 5: Deburring and Painting

The final stages involve deburring all sharp corners to ensure the component is safe to handle and free from imperfections. Following this, the component is prepared for painting, adding an extra layer of protection and aesthetic appeal.

Step 6: Final Touches and Shipping

Once painting is complete, the refurbished bottom crosshead is carefully packaged for shipment. This particular piece was destined for Chile, ready to rejoin its press and resume its essential role in the manufacturing process.

A Sustainable Approach to Manufacturing

The refurbishment of old presses not only revives valuable machinery but also promotes a sustainable approach to manufacturing. By extending the life of these machines, we reduce waste and provide our clients with a cost-effective solution for maintaining operational efficiency.

At Dieffenbacher North America, our commitment to quality and innovation drives us to continually find new ways to meet our customers’ needs. Whether it’s refurbishing an old press or developing cutting-edge technologies, we are dedicated to advancing the field of manufacturing for a better, more sustainable future.

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