Grinding wheel technology

The grinding wheel press is designed for the production of highly efficient CBN and diamond grinding wheels with carbon backing pads. For precise and reproducible shaping, the system is equipped with a rotary table for even filling, a sliding table, and an ejector.

The large-format grinding wheel press is designed for the production of ceramic and resin-bonded grinding wheels with a diameter of up to 1,330 mm. The double sliding table in a 90° arrangement enables efficient alternating operation and short downtimes. With a pressing force of 3,000 t, the system ensures high dimensional accuracy and consistent product quality, even for large-format grinding wheels.

The universal grinding wheel press is equipped with inductive tool heating, enabling the tool to be heated quickly to up to 600°C. The combination of high closing speed and precise pressure build-up ensures short cycle times and reproducible product quality for a wide range of grinding wheel applications.

The production plant is designed for the manufacture of carbon fiber reinforced carbon components (CFC). The stacks are prepared under controlled conditions at a separate packing station to prevent the spread of carbon fiber dust. This is followed by fully automatic feeding to the two-stage press, where the components are consolidated under pressure and temperature. The finished components are automatically removed and fed to the next process step, ensuring a consistently efficient production flow.

The seven-stage laminating press is used to produce high-quality laminates for aircraft cabin interiors (“aircraft wallpaper”). The fully automated system enables a loading and unloading cycle of less than two minutes, significantly reducing press downtime. The loading and unloading process takes place in a separate room, while the product circulation is carried out via transport trays to ensure a continuous and efficient production process.

The large-format frame press with a pressing force of 1,350 tons and integrated sliding table is designed for the development of novel composite components. Its robust construction and flexible design enable a high degree of process diversity and maximum adaptability when testing innovative material and manufacturing concepts.

The press has a pressing force of 300 t and active parallelism control with an accuracy of 0.025 mm. In combination with variothermal temperature control, it is optimally designed for the development of innovative composite components in the automotive industry. An integrated extraction system reliably removes vapors generated during the processing of special materials, while a vacuum tank enables rapid evacuation of the mold, thus supporting efficient process flows.

This press is used to manufacture large-format rotor blades using the RIM process for the production of air-water recooling systems for petroleum processing. For ergonomic operation, the upper part of the tool, measuring up to 5,000 x 1,600 mm, can be swiveled 90° toward the operator.

High-performance thermoplastics are processed on an area of up to 2,000 x 1,000 mm. The connected IR preheating oven brings the components to a temperature of up to 450°C in the shortest possible time. The subsequent component transfer to the press takes less than 6 seconds.

The WKP 6 000 S is a high-precision hydraulic press that has been specially designed for the development of thermoforming and consolidation processes. Equipped with electrically heated heating plates, it enables precise temperature control up to 450°C. Maximum process speed is ensured by high-speed handling, which transfers the clamping frame including the raw part from the infrared oven to the press at maximum speed. It takes less than 4.5 seconds from leaving the oven to completely closing the press – ideal for dynamic processes in research and development. This versatile press is designed not only for processing composite materials, but also for a wide range of other materials, including particle foams and high-performance metal alloys.

The WKP 5 000 S is a high-precision hydraulic press specifically designed for the development of thermoforming and consolidation processes. Equipped with thermal oil-heated press platens, it offers exceptionally accurate temperature control of ±0.5K – even at platen temperatures of up to 410°C and heating rates of 20K/min. To ensure maximum process speed, a high-speed handling system rapidly transfers the clamping frame including the blank from the infrared oven into the press. From the moment it leaves the oven to the complete closure of the press, less than 3 seconds elapse – making it ideal for dynamic process workflows in research and development.

With transfer handling, components presented outside the press can be transferred very quickly and with only a minimal press stroke. This reduces the open time/machine time of the press to a minimum, which maximizes the output. The press can be interlinked with the upstream process or operated manually for small series / prototypes. With a quick-change mold system, a wide range of mold sizes and therefore component sizes can be processed and either components can be “nested” with 2 cavities each or large friction discs can be hot-bonded.

We boost / automize your press-processes. A previously manual process becomes a fully automated process: Fully automatic loading and unloading of fragile components into / from a hot bonding press for pressing / calibrating the components with the highest possible precision. Up to 4 hours unmanned production: With the solution shown, the system in the application example can produce completely independently for 4 hours. No interruption of the production process necessary. The lock principle even ensures, that the magazine can be emptied / refilled during ongoing production.

The system is specially designed for the fully automatic production of cylinders or hollow cylinders made of free-flowing PTFE. Since free-flowing PTFE loses its pourability at temperatures above 18°C, the entire material feed system is air-conditioned to ensure that temperatures remain below 18°C.

The entire system consists of a powder press and an isostatic re-densification unit. The special feature is that both systems are controlled by a common control and hydraulic system. This saves space and investment costs. The maximum compaction pressure in the press is 2,000 bar, and as much as 3.500 bar in the downstream isostatic pressing.

The continuous press system consists of two hot presses, two cooling presses, automatic loading, automatic product unloading and automatic release agent supply. The high degree of automation of the system allows the entire system to be supervised by just one person. There are always 5 moulds in use at the same time. 4 moulds in the two hot and cooling presses. The fifth mould is located outside the press for unloading, cleaning, spraying release agent and loading.

The large-format molds are filled fully automatically via an extruder. The extruder is also suitable for compensating mass loss during cooling in the mold using the “holding pressure” function. The maximum product weight is 500 kg. The state of the art for this process is a variothermal process with a very large variothermally moved weight. Due to the fact that the material does not have to be melted in the mold, it is possible to work with significantly lower maximum temperatures in the mold. This saves cycle time and energy.

Beech veneers are pressed fully automatically into highly compressed laminated densified wood on the three-daylight press. In addition to the high specific pressure, a variothermal process control with good temperature distribution is a success factor. The temperature control is done by a pressurized water temperature control system

Rubber expansion press for the highest demands – virtually no “tipping” during the manufacture of high-quality rubber products. Absolute plane parallelism between the heating plates. Tolerance +/- 0.05 mm. 4 measuring points for position detection. Constantly low temperature in the press table thanks to additional water temperature control. Precise and reproducible expansion speeds can be set. Heating plates divided into 15 zones for the most homogeneous temperature distribution.

Rubber vulcanisation press with vacuum chamber and vacuum reservoir for rapid ‘evacuation’ of the press chamber. For high and precise product requirements without air inclusions. Modern 6-zone control for homogeneous temperature distribution. Upper and lower lifting unit for ‘demoulding’ when using multi-part pressing tools. Central ejector at the bottom for easy and simple ejection of products. Adjustable mould change consoles to change different pressing tools as quickly and easily as possible

The vacuum chamber press is used to manufacture large gaskets and large rectangular parts. The heating plate and vacuum chamber are therefore square. The sliding table is used to move the lower part of the mold together with the lower heating plate in front of the machine, thus ensuring good ergonomics for the operator in this position.

The vacuum chamber press has been specially developed for the production of large elastomer seals. The vacuum chamber reliably prevents unwanted air pockets in the seal. The fact that only round tools are used on this machine allows for a round heating plate and a round vacuum chamber. The main advantage of this configuration is significantly improved accessibility and thus significantly improved ergonomics for the operator, especially when inserting blanks into the lower tool. This ergonomic advantage is particularly beneficial for tools with a diameter of <1500 mm. Another advantage of the round heating plates is that the heating plate size can be reduced by more than 20%. This saves energy.

Modern laboratory press with clean room housing. Smooth surfaces and no interfering edges in the press interior make cleaning easy. Dirt collection funnel at the rear to collect material residues. 6-zone “electrical” control (in accordance with ISO 2393). Tool vacuum for pressing tests without air pockets. Process parameters can be loaded very easily using a barcode scanner.

Fully interlinked hot-bonding cell that receives components to be calibrated from the upstream process, cools them after pressing and then conveys them to the downstream process.

Fully interlinked Hot-Bonding cell that either receives components to be calibrated from the upstream process inline or can also process them decoupled with component magazines and then convey them to the downstream process after Hot-Bonding/Calibration Process.

600 to hot bonding press, which also enables high-precision cold embossing/cold calibration of friction linings thanks to its high pressing force.

Press hardening of wear parts for agriculture with indirectly cooled tools.

The 3-station fixture hardening press is designed for fully automatic operation. It is suitable for large batch sizes and is usually equipped with fully automatic furnace loading and unloading systems, component buffer systems, post-cooling basins, cleaning stations and also with a direct link to the tempering process. The extensive PLC control system of the press is the master and controls all movements of all plant participants and transfers all process and production data to the higher-level MES systems via computer interface.

The 2-station fixture hardening press is designed for fully automatic operation. It is suitable for medium to large batch sizes and is usually equipped with fully automatic furnace loading and unloading systems, component buffer systems, post-cooling basins, cleaning stations and also with a direct link to the tempering process. The extensive PLC control system of the press is the master and controls all movements of all plant participants and transfers all process and production data to the higher-level MES systems via computer interface.

As soon as large and heavy components are handled, handling / gripping usually takes place from above. With the hardening press with hydraulic sliding table, the lower hardening die can be loaded from above. The press can be operated with an expanding mandrel as well as with a fixed mandrel.

Fixture hardening press for hardening large gears with a mandrel press-out force of 80 tons. The press is equipped with a fully automatic handling system and robots and is designed for a component weight of 70 kg. The special feature of the system is the fully integrated operation of all plant participants, such as an austenitizing furnace and deep-freezing and tempering furnaces. All process data is recorded and securely stored in accordance with the applicable regulations for aerospace industries.

The WKP 4 400 S is specifically designed for thermoforming and consolidation processes. Equipped with electrically heated platens, it allows precise temperature control up to 450 °C. An integrated recooling system enables the platens to be rapidly cooled down to below 50 °C when needed. Thanks to the high-speed handling system, the clamping frame including the blank is transferred from the infrared oven into the press in less than 2 seconds. Including the press closing time, the entire process takes less than 5 seconds.

The WKP 1 700 S is specifically designed for thermoforming and consolidation processes. Equipped with electrically heated platens, it allows precise temperature control up to 400 °C. An integrated recooling system, operating in a closed loop water circuit, enables the platens to be rapidly cooled down to below 50 °C when needed – resource-efficient and effective. Thanks to the high-speed handling system, the clamping frame including the blank is transferred from the infrared oven into the press in less than 2 seconds. Including the press closing time, the entire process takes less than 5 seconds.

Wickert supplies fully automatic press systems for calibrating and hot bonding these friction discs, which enable both maximum precision in temperature control in the tool and maximum geometric precision in the tool, which in turn has a positive effect on the thickness variance of the friction lining itself and not only on the reliable bonding of the friction layers to the steel carrier. Depending on the desired output quantity, the presses themselves can be operated with the corresponding automation concept in “nested bonding” with several cavities or individually manually in a single-station concept. The traceability of production and process data, which is transferred to the customer's higher-level MES systems, plays a key role here.

For the production of a combination of a multi-daylight press and an automated loading and unloading device, the open time of the press can be reduced to a minimum. In addition to high-performance temperature control, this is a key factor in increasing system efficiency.

The assembly cell consists of a fitting press and a positioning press. Rotor shafts and rotor packs are fitted on the fitting press with a fitting force of up to 600kN. The positioning press compensates any possible faults in radial run-out. Both the fitting and positioning presses set themselves up fully automatically for different product sizes. A laser is used to apply a corresponding barcode to the product after a successful fitting and positioning process.

The large-format compression press is equipped with an integrated extension device for the upper tool and achieves a flat parallelism of 0.1 mm across the entire press surface of 3,300 x 3,600 mm. This high dimensional accuracy ensures even pressure distribution and reproducible component quality, especially in the manufacture of large-format molded parts.

The SMC press has an opening force of up to 1,000 kN and is specially designed for processing sheet molding compound (SMC). Automatic tool clamping and a tool change table enable fast setup processes and high system availability. The intelligent control software supports different press stages and ensures precise, reproducible process control for varying material requirements.

The fully automatic grinding wheel press is designed for a fully automated production process. The equipment includes a single chamber, smoother, upper punch handling, a double sliding table, and turntables with integrated ejector. This combination enables precise and reproducible production at high process speeds and with minimal operating effort.

The combination of modern, energy-efficient press control and highly dynamic heating/cooling system enables very precise pressure and temperature control when consolidating modern laminates made of high-performance thermoplastics. Heating rates of up to 55K/min enable significantly shorter cycle times and create new possibilities in the processing of thermoplastics.

With a table size of 2.5 x 2.2 m and a pressing force of over 1,000 t, the WKP 10000 S sets new standards in the production of RTM components. In addition to a very sensitively adjustable pressing force, the press is characterized by a parallelism of 0.05 mm. This is achieved by the specially developed parallelism control for positioning the movable pressing plate.

Large-format semi-finished products made of PP and PE measuring 6 x 2 m are manufactured in a variothermally heated mold. The integrated thermal oil system provides sufficient heat energy to heat the mold mass of almost 20 t in a short time.

The fully automatic WKP 600 R thermoforming system sets new standards in the processing of PPS and PEEK composite materials. It combines the highest product quality, excellent process documentation and the ability to efficiently produce small quantities. A handling robot first transfers the blanks to one of the two IR preheating ovens and then to the press. An extremely short transfer time of less than 6 s ensures that the forming process takes place exactly within the optimum temperature window. A specially developed gripper begins preforming before the actual pressing, before the final shaping takes place in the press. A second robot cyclically applies release agent to maximize tool protection and process stability. It also enables fully automatic, high-frequency tool changing by inserting preheated tools into the press.

Fully interlinked press for forming and hardening sheet metal components with polymer with max diameler ø1000mm. The hardening press is fully interlinked with an austenitizing furnace (roller hearth) and controls all movements from furnace loading handling to transfer handling with camera position detection of the components from the furnace to the press, as well as fully automatic stacking of the components after pressing for the subsequent tempering process. With a quick die change system, die changes can be set up quickly and clamped fully automatically. As soon as the press is running again, the tool can be changed over safely and ergonomically. The press is designed for fully automatic operation with robot systems, but can also be operated manually for small batches. The components in the closed tool are sprayed with polymer-water quenching agent. This is reliably and permanently filtered inline in a closed-loop circuit and thus guarantees a consistent, trouble-free hardening process. All process parameters - including those of the oven - are monitored by the press control system and thus guarantee full process control.

Fully interlinked press for quenching flat components with cooling plates. The hardening press is fully interlinked with an austenitizing roller-hearth furnace and controls all movements from furnace loading handling to transfer handling from the furnace to the press and also after pressing for fully automatic stacking of the components for the subsequent tempering process. All process parameters - including those of the furnace - are monitored by the press control system, thus guaranteeing full process control.

The high-temperature press is designed for the production of CBN and diamond grinding wheels at process temperatures of up to 500 °C. Highly efficient thermal insulation ensures stable temperature conditions, while precise force application and release guarantees uniform compaction and high component quality.

The 1-station quenching press is designed for both manual and fully automatic operation. It is suitable for small to medium batch sizes and can be optionally equipped with upstream and downstream handling systems, post-cooling basins, cleaning stations and also deep-freezing and tempering combinations.

Fully interlinked press for forming and hardening sheet metal components with polymer. The hardening press is fully interlinked with an austenitizing furnace (roller hearth) and controls all movements from furnace loading handling to transfer handling with camera position detection of the components from the furnace to the press, as well as fully automatic stacking of the components after pressing for the subsequent tempering process. With a quick die change system, die changes can be set up quickly and clamped fully automatically. As soon as the press is running again, the tool can be changed over safely and ergonomically. The press is designed for fully automatic operation with robot systems, but can also be operated manually for small batches. The components in the closed tool are sprayed with polymer-water quenching agent. This is reliably and permanently filtered inline in a closed-loop circuit and thus guarantees a consistent, trouble-free hardening process. All process parameters - including those of the oven - are monitored by the press control system and thus guarantee full process control.

Hot bonding press for large friction discs with a sliding table for ergonomic loading and unloading of very large friction discs. The tool concept enables tools to be changed in less than 10 minutes. High-precision temperature control ensures consistent process parameters even with multiple loading.

With the 3-deck hot bonding press, large friction plates can be bonded/calibrated in the same heating time. With the footprint of one press, several components can be bonded on top of each other with the same cycle time. This makes the press a cost-effective and space-saving solution.

The manual powder press was specially developed for the manual production of graphite plates. In particular for powders that are so badly free-flowing that they are not suitable for automatic dosing.

The large-format column press is equipped with a double sliding table and enables two tools to be operated in parallel. While one lower tool section is under pressure in the press, the second can be unloaded, cleaned, and reloaded outside the press. This concept reduces downtime and enables production throughput to be almost doubled.