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Structural Integrity for Forging Machines in an Aged Plant
Innovative Engineering Ensures Safe Installation of High-Capacity Forging Machines in a Structurally
Challenged Environment
When designing or operating a plant, especially one with heavy machinery, ensuring stability and longevity is a top priority. Vibration from high-capacity forging hammers and presses can severely impact both the machinery and the surrounding structures. For plant operators and designers, finding effective solutions to minimize these vibrations is critical to maintaining productivity, safety, and equipment lifespan. This case study highlights an effective vibration isolation solution for a large forging hammer installed in a long-standing plant. The challenges were significant, but through innovative design and engineering, a robust solution was implemented. Read on to discover how GERB took up these challenges and provided a solution that enhanced the plant‘s capabilities without compromising its structural integrity.
Challenge
A large forging company acquired an existing plant that was over 30 years old. The plant housed metal forming presses installed in a common pit. The new owners intended to install several high-capacity forging hammers and presses in the same facility. However, they faced a major challenge: the plant‘s structure was weak, and the existing pit was too large to support these new machines effectively.
Excavating a deep foundation posed a significant risk of destabilizing the old plant structure, and utilizing the existing pit without modifications could lead to further complications. Constructing a new foundation within the pit would have exposed the substructure to high dynamic forces from the forging machines, potentially causing structural damage. Hence, the need for an effective vibration isolation system was essential to prevent any adverse effects on the plant’s infrastructure.
Solution
GERB was invited in 2019 to assess the site and provide a viable solution. The GERB team conducted a thorough review of the site, analyzed old construction drawings, and carefully considered the static and dynamic forces generated by a 275 kJ forging hammer. With these insights, GERB developed a balanced design that effectively addressed concerns about machine-induced vibrations and amplitudes. The proposed solution involved a low-frequency isolation system tuned to 4 Hz, coupled with appropriate damping. This setup ensured that the hammer would come to a complete stop before initiating the next stroke, minimizing vibrations and protecting the plant’s structure. The purchase order for the solution was finalized in early 2020, and by the end of the same year, the GERB system was successfully installed. The hammer was commissioned and began operation by early 2021.
Technical Facts:
Vibration source: Forging Hammer
Base isolation frequency: 4 Hz
Design load: 720 t
Base isolation: GERB GP spring elements and Viscodampers®
Result
After the hammer was put into operation, vibration measurements were taken to assess its performance and the machine’s behavior. The results were impressive, showing very low vibration transmission levels. The maximum velocity recorded was 0.3 mm/s at a distance of 20 meters and approximately 0.18 mm/s in the tool room area— well below the limits specified in the DIN 4150 Part 2 guidelines. This confirmed the effectiveness of GERB‘s vibration isolation system in maintaining safe operational levels within the plant.
Due to the successful implementation, GERB was awarded the contract to isolate another hammer with a blow energy of 175 kJ in the same pit in 2021. This project was completed promptly, and now two hammers operate efficiently in a 30+ year old pit that was constructed for sheet metal presses.
GERB‘s innovative approach allowed the safe and efficient installation of high-capacity forging machines in an aging plant, significantly extending the facility‘s operational life and capabilities.
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Further Resources
You need further information on this topic?
Please do not hesitate to contact us with your individual question.
One of our project engineers will get back to you shortly.
Structural Integrity for Forging Machines in an Aged Plant
Innovative Engineering Ensures Safe Installation of High-Capacity Forging Machines in a Structurally Challenged Environment
When designing or operating a plant, especially one with heavy machinery, ensuring stability and longevity is a top priority. Vibration from high-capacity forging hammers and presses can severely impact both the machinery and the surrounding structures. For plant operators and designers, finding effective solutions to minimize these vibrations is critical to maintaining productivity, safety, and equipment lifespan. This case study highlights an effective vibration isolation solution for a large forging hammer installed in a long-standing plant. The challenges were significant, but through innovative design and engineering, a robust solution was implemented. Read on to discover how GERB took up these challenges and provided a solution that enhanced the plant‘s capabilities without compromising its structural integrity.
Structural Integrity for Forging Machines in an Aged Plant
Innovative Engineering Ensures Safe Installation of High-Capacity Forging Machines in a Structurally
Challenged Environment
When designing or operating a plant, especially one with heavy machinery, ensuring stability and longevity is a top priority. Vibration from high-capacity forging hammers and presses can severely impact both the machinery and the surrounding structures. For plant operators and designers, finding effective solutions to minimize these vibrations is critical to maintaining productivity, safety, and equipment lifespan. This case study highlights an effective vibration isolation solution for a large forging hammer installed in an aging plant. The challenges were significant, but through innovative design and engineering, a robust solution was implemented. Read on to discover how GERB tackled these challenges and provided a solution that enhanced the plant‘s capabilities without compromising its structural integrity.
Challenge
A large forging company acquired an existing plant that was over 30 years old. The plant housed metal forming presses installed in a common pit. The new owners intended to install several high-capacity forging hammers and presses in the same facility. However, they faced a major challenge: the plant‘s structure was weak, and the existing pit was too large to support these new machines effectively.
Excavating a deep foundation posed a significant risk of destabilizing the old plant structure, and utilizing the existing pit without modifications could lead to further complications. Constructing a new foundation within the pit would have exposed the substructure to high dynamic forces from the forging machines, potentially causing structural damage. Hence, the need for an effective vibration isolation system was essential to prevent any adverse effects on the plant’s infrastructure.
Challenge
A large forging company acquired an aging plant that was over 30 years old. The plant housed metal forming presses installed in a common pit. The new owners intended to install several high-capacity forging hammers and presses in the same facility. However, they faced a major challenge: the plant‘s structure was weak, and the existing pit was too large to support these new machines effectively.
Excavating a deep foundation posed a significant risk of destabilizing the old plant structure, and utilizing the existing pit without modifications could lead to further complications. Constructing a new foundation within the pit would have exposed the substructure to high dynamic forces from the forging machines, potentially causing structural damage. Hence, the need for an effective vibration isolation system was essential to prevent any adverse effects on the plant’s infrastructure.
Solution
Technical Facts:
Vibration source: Forging Hammer
Base isolation frequency: 4 Hz
Design load: 720 t
Base isolation: GERB GP-elements and Viscodampers®
GERB was invited in 2019 to assess the site and provide a viable solution. The GERB team conducted a thorough review of the site, analyzed old construction drawings, and carefully considered the static and dynamic forces generated by a 275 kJ forging hammer. With these insights, GERB developed a balanced design that effectively addressed concerns about machine-induced vibrations and amplitudes. The proposed solution involved a low-frequency isolation system tuned to 4 Hz, coupled with appropriate damping. This setup ensured that the hammer would come to a complete stop before initiating the next stroke, minimizing vibrations and protecting the plant’s structure. The purchase order for the solution was finalized in early 2020, and by the end of the same year, the GERB system was successfully installed. The hammer was commissioned and began operation by early 2021.
Result
After the hammer was put into operation, vibration measurements were taken to assess its performance and the machine’s behavior. The results were impressive, showing very low vibration transmission levels. The maximum velocity recorded was 0.3 mm/s at a distance of 20 meters and approximately 0.18 mm/s in the tool room area— well below the limits specified in the DIN 4150 Part 2 guidelines. This confirmed the effectiveness of GERB‘s vibration isolation system in maintaining safe operational levels within the plant.
Due to the successful implementation, GERB was awarded the contract to isolate another hammer with a blow energy of 175 kJ in the same pit in 2021. This project was completed promptly, and now two hammers operate efficiently in a 30+ year old pit that was constructed for sheet metal presses.
GERB‘s innovative approach allowed the safe and efficient installation of high-capacity forging machines in an aging plant, significantly extending the facility‘s operational life and capabilities.
Solution
GERB was invited in 2019 to assess the site and provide a viable solution. The GERB team conducted a thorough review of the site, analyzed old construction drawings, and carefully considered the static and dynamic forces generated by a 275 kJ forging hammer. With these insights, GERB developed a balanced design that effectively addressed concerns about machine-induced vibrations and amplitudes. The proposed solution involved a low-frequency isolation system tuned to 4 Hz, coupled with appropriate damping. This setup ensured that the hammer would come to a complete stop before initiating the next stroke, minimizing vibrations and protecting the plant’s structure. The purchase order for the solution was finalized in early 2020, and by the end of the same year, the GERB system was successfully installed. The hammer was commissioned and began operation by early 2021.
Technical Facts:
Vibration source: Forging Hammer
Base isolation frequency: 4 Hz
Design load: 720 t
Base isolation: GERB GP-elements and Viscodampers®
Result
After the hammer was put into operation, vibration measurements were taken to assess its performance and the machine’s behavior. The results were impressive, showing very low vibration transmission levels. The maximum velocity recorded was 0.3 mm/s at a distance of 20 meters and approximately 0.18 mm/s in the tool room area— well below the limits specified in the DIN 4150 Part 2 guidelines. This confirmed the effectiveness of GERB‘s vibration isolation system in maintaining safe operational levels within the plant.
Due to the successful implementation, GERB was awarded the contract to isolate another hammer with a blow energy of 175 kJ in the same pit in 2021. This project was completed promptly, and now two hammers operate efficiently in a 30+ year old pit that was constructed for sheet metal presses.
GERB‘s innovative approach allowed the safe and efficient installation of high-capacity forging machines in an aging plant, significantly extending the facility‘s operational life and capabilities.
Share this post
Share this post
Further Resources
You need further information on this topic?
Please do not hesitate to contact us with your individual question.
One of our project engineers will get back to you shortly.
Further Resources
You need further information on this topic?
Please do not hesitate to contact us with your individual question.
One of our project engineers will get back to you shortly.