EXCELLENCE AND INNOVATIVE SOLUTIONS

 

SACMA to be well known by the world manufacturers of fasteners and special parts. Every day more than 6500 SACMA machines are operative through out the world, in hundreds of factories, transforming thousands of tons into high quality fasteners and special parts, used in many different industrial applications.

Products

PROGRESSIVE HEADERS

Netshape Part Formers

Sacma Progressive Headers are available in several models up to 33mm diameter cutoff capacity and feature the most advanced controls and systems for forming net and near net shapes with consistent and repeatable tolerances up to 350ppm.  Some of the unique features include: One piece cast bed frames and heading slides with forged crankshafts for maximum rigidity and stability for the tooling and machine components gives precise part forming and reduced maintenance cost.

 

The Sacma Desmodrive transfer design is the most reliable, accurate and lowest maintenance cost transfer available.  The transfer provides the most flexibility of any design, allowing our customers the ability to form a wide range of part shapes and the ability to actually form nut and bolt shapes on the same machine.  The pressure of the fingers is driven by pneumatic cylinders allowing the customers to run very short parts and extra-long parts with the transfer unit.

 

The computerized S-Feed Electronic wire feeder provides the operator the most accurate and precise cutoff volume control of any former available. The patented “S-Feed” system is driven by servomotors with a self learning adjustment making the cut-off operation adjustment very easy for the operators.

 

A full range of options are available including our Electronic Handwheel jog control that provides precise slow motion control of the machine movement for obtaining extremely accurate setups for closer part tolerances and reduced setup times.  The machine position can be instantly adjusted either forward or backward, reducing the setup time.

COMBINED HEADERS

Forming, Pointing and Thread Rolling All in One Machine

The Combined Headers models are available to run fasteners from M4 to M24. The combined header provide the best solution for high productivity requirements, consolidation of production methods, floor space usage and work flow in a fastener manufacturing environment by having the forming, pointing and thread rolling all in one machine. Sacma Combined Headers provides maximum efficiency and part quality in the manufacturing process of standard fasteners and special automotive fasteners by producing the finished product directly from wire.

 

Featuring all the mechanical and performance qualities of the Progressive Headers, SACMA Combined Headers offers the ability to make the quick changeovers and the versatility to make net shape parts in addition to bolts and screws. This demonstrates Sacma’s innovative real modular system making the well-earned reputation of versatility, quality, precision, reliability and longevity the best value for your investment. The large number of combined headers installed yearly worldwide is the best demonstration of these very successful high-performance machines.

 

As per the Progressive Headers, a full range of options are available to extend the capacity of the machine with the quick changeover. The Combined Header can also run headless parts and can be equipped with a heating unit to run stainless parts or special materials.

WARM FORMERS

 For Special Materials

Sacma offers the only production proven, fully integrated Warm Former available for the high efficiency production of high tensile strength materials like those used in aerospace and high temperature applications. Combining the state of the art controls and automatic support systems with the advanced induction heating units heats the wire to the center to give very precise control of the material deformation for forming consistent near net part shapes with repeatable tolerances.

 

The Warm Formers are equipped with a set of standard features permitting to manage the production automatically by PLC and interface Touch Screen panel control with dual Induction coil up to 150kW; spot heating coil when it is necessary to heat only the wire portion to be caulked; coolant liquid system for the cut-off station, die block, and frame; thermoregulation system for automatic heating or cooling the machine for optimal operation temperature from startup and throughout the production run; integrated fire extinguishing system, with flame detection sensors and CO2 spray nozzles; automatic motorized adjustments of the positioning of the stock gage tip and of the threaded sleeve, allowing corrections of the cut-off blank length and of the position of the die ejector pins, during production without stopping the machine; Touch Screen Controls for the settings control & full monitoring of the heating, thermoregulation and machine systems; S-Feed wire feeder for precision length control & automatic retraction of the wire from the induction coils when the machine stops.

 

The Warm Formers are the result of a concentration of best technologies applied to headers to create the most precise and reliable machine available for the Aerospace and Automotive Fastener Industries.

LARGE PARTS FORMERS

 For Heavy & Large Parts

For the large components production, the Large parts Formers are available designed to produce hollow and solid special parts for the most different industries. These machines is unique for its performance and equipment. Up to 650 tons are available to form large components normally manufactured by vertical presses or other traditional technologies with a longer production process. The header can be equipped with a system to feed the heading station with blanks or to re-feed pre-formed parts in the required station in making the machine a true Forming center. The machines are entirely equipped with automatic adjustments and quick tool change system driven by robotized manipulator.

 

This SACMA series 6, not only represents the “excellence“ of the Sacma technology, but is also considered the world benchmark for large size cold formers. These large 6die cold formers are available in the shorter “AS” version (DKO 160 mm) and the longer “AL” version (DKO 240 mm), proposing very interesting innovative concepts with respect to ergonomics, safety and flexibility for production of very short and long components. As per all the Sacma Group machines, the size 6 is Industry 4.0 ready.

COMBINED DOUBLE BLOW HEADER

 

ALL-IN-ONE to run fasteners from M3 to M8 with max. shaft length 60 mm.

 

The KSP12-R combines typical SACMA solutions, proven by thousands of machines, with the most advanced mechatronic technology available in the market. The one-piece main frame, cast perlitic iron, normalized, natural aged for at least 12 months, high precision machined, is a guarantee of rigidity and stability for all the machine life. Major set up adjustments are now motorized for a quick and friendly changeover: S-feed wire feeder driven by torque motor, motorized wire stock gauge and DKO, threading starter driven by torque motor with self-learning function borrowed from Ingramatic rollers. The quality management is facilitated by two gates interfaced with the load monitoring system and discharging NC parts respectively after the header and after the roller. An optional sophisticated load control system is protecting the machine against overloads and is monitoring the forming and rolling processes. Scraps separators in different sizes are available when producing self-tapping screws.

 

All those features make the KSP12-R the best value for Customer’s investment, especially when running parts traditionally by a line of connected machines. The high productivity ALL-IN-ONE allows to quick return and the legendary long life guarantees future profits.

Download Sacma Catalogue 2.5 MB

In this section you can see the clear picture of what are the Winning Technologies® that have made SACMA so famous and successful in the world.

MONOBLOCK MAIN FRAME

Among the different methods of manufacture SACMA has chosen the monoblock casting made of perlitic spheroidal cast iron, normalized and stabilized by ageing in excess of 12 months, to guarantee the maximum rigidity and the highest level of stability under heavy loads.

ULTRA PRECISION

The correct choice of high tensile materials, the proper heat treatment specifications, the accuracy of surface finish operations of grinding and lapping make a  SACMA machine the most reliable, the most productive and lowest cost machine in manufacturing.

QUICK TOOL CHANGE

The CR  Quick Tool change system, standard for machines series 3, 4, 5 and 6, allows for easy removal of the die block, hydraulic clamped, and just as easy removal of the punch block bolster and the complete transfer unit

TOOL PRESETTING

The SACMA  CR Quick Tool Change machines, designed to perform production changes in a short time, still maintain the renowned characteristics of robustness, precision, reliability and efficiency, typical of a  SACMA machine.

 

The SACMA machines can be equipped with an external Presetting Bench for setting the tools.

 

The Presetting Bench allows one to perform, outside of the machine, an accurate alignment of the punches to the dies, the correct axial position of the punches, and the perfect setting of transfer fingers. This procedure can best be performed in the tool room area, so that correct preset tools are delivered to the machine for the next job. This allows a more rational utilization of the factory floor space and the optimization of the company’s technical resources.

MOTORIZATION

The M automatic motorization system available on SACMA progressive and combined machines, is an important method for reduction of machine set up time and fine tuning of adjustments. The preset data present in the data base of parts to be manufactured will determine the automatic adjustments of feed, position of stock stop, and die kick out. The new SP 670 model 6 die cold former can be fitted with the individual automation of adjustments of finger timing cams.

 

The motorized machines utilize the SACMA SC-MATIC Software developed on Siemens platform and operative with Windows-CE. Data base in excess of 20.000 different part numbers can be stored in thestem which will also display all alarm information relative to machine stoppage. The system also has an Ethernet port for transfer of data and a modem which can be activated for teleservice.

MONITORING SYSTEMS

All SACMA machines can be fitted with state of the art control and onitoring systems, developed in conjunction with a leading manufacturer in this field:

 

SC10: short feed control system, available for all machines but fitted as standard on all CRM progressive and combined machines;

SC500: forging load monitoring system, calibrated to give a true reading in KN of the loads acting in the main frame of the machines, at every blow. Available on all progressive and combined machines;

SC600: roll forming load monitor, with sensors located directly behind the fixed roll die and complete with a discharge gate to eliminate bad parts.

Available on all combined machines.

 

Any one machine can also be specially prepared to receive load monitoring systems of other brands.

HYDRAULIC CLAMPING

Hydraulic clamping of adjustments and tools is of great help when setting the machine and guarantees repeatability of the adjustments. Clamping and unclamping is easily performed by the touch of a switch, avoiding any manual work with wrenches inside the machine enclosure.

 

All SACMA machines are fitted standard with hydraulic clamping of die side adjustments of threaded sleeves, kick out levers and trim cam in the last station.

PERFECT CLEARANCE HEADING SLIDE

All SACMA machines heading slides are made of NiCrMo alloy steel casting, heat treated and having a special geometric shape with double slide ways to offer maximum stability in delivering the forging energy to the tools.

TRANSFER SYSTEM

The real heart of high speed horizontal cold formers is represented by the transfer mechanism which has to be able to bring parts from one station to the other: only with a precise and infallible grip can one obtain best results of efficiency and productivity.

 

The transfer mechanism of SACMA Progressive and Combined headers is by far considered the world benchmark, so much, that it has been subject of numerous unsuccessful imitation attempts by others.

TRANSFER SUPPORT ASSIST PACKAGE

The well known and great capability of the SACMA transfer to handle difficult and short parts, now becomes all the more versatile with the introduction of a patented SACMA transfer support assist package, that can transfer conical or shoulder parts which would tend to fall on die kick-out.

SERVICE  EQUIPMENT

The patented system of ergonomic platforms and tool cradles supplied by SACMA on the Series 6 machines is a very good example of assistance, without compromise, to the requirements of the end user. The system consists of two hydraulic operated platforms that position themselves automatically over the work area:

 

○ The lower platform used for tool change, receives special tool cradles for fitting or removing dies and punches;

○ The upper safety platform is used for intervention of the operator when changing or setting transfer fingers and timing cams.

 

Manipulation of die boxes, punch block bolsters and transfer finger units are performed by means of special cranes that can be fitted on Customer’s request:

 

○ Gantry portal crane with electric hoist having three dimensional motorized movements;

○ Automatic motorized portal manipulator with preset positions for pick up and delivery of tool holders. Available on the Series 6 machines.

ELECTRONIC HANDWHEEL

With the intention of assisting best the tool setters in the delicate moment of tool and timing adjustments, SACMA has developed an electronic andwheel to move the whole machine at slow motion in order to check for correct timing of the transfer fingers with respect to the heading slide, avoiding dangerous collisions. The heading slide can be stopped in any position avoiding machine jogging and damaging the main clutch/brake unit.

COMBINED MACHINES

The proper and best answer to high productivity requirements, rationalization of production methods, floor plan lay-out and material flow in a fastener manufacturing environment is represented by machines that have forging, pointing and thread rolling stations, all in one.

 

These machines will determine maximum efficiency and quality in the manufacturing process of standard fasteners and special automotive fasteners, because they supply the finished product.

The SACMA Combined headers maintain all the mechanical and performance qualities of the Progressive headers, from which they derive. The pointing and the thread rolling units are designed and manufactured to be user friendly and easy to set up, to produce many different shapes of points.

WARM FORMING

The application of a warm forming system to horizontal forging machines extends the possibility of making netshape parts of more complex shapes and to work with special materials which could not be forged cold.

 

In order to meet these new requirements in the industry, SACMA has developed special machines, incorporating induction heating units in the feeding areas.The typical temperature range of warm forming applications is between 400°C and 900°C.

High frequency induction heating is obtained by means of special coils that can be fitted outside or inside the main frame of the machine, between the feed rolls and the cut-off quill.

 

There is a specific cooling of the coils and of the frame and the temperature of the wire is read by specific optical pyrometers. The WF application can then be completed with temperature control of the die box and of the coolant liquid

TOOL DESIGN

The long term experience and know-how that SACMA has of analysis of forging problems and in the research of suitable technical solutions, which are then shared with the customer, makes us a valid partner to be of assistance during the critical stages of development, to bring the project to a successful solution in the shortest possible time. A team of project engineers, assisted by modern design and calculation software, works together with the customer to reach the best manufacturing solutions for the industrial development of the product. With the co-operation of other leading companies in our industry,  SACMA is also able to suggest efficient turn key solutions of the projects

SacmaForm®

SACMA, with the cooperation of the Mechanical and Application Engineering Department of Padua University, developed the SacmaForm®; application software, which gives tool designers a valid method and assistance for the initial engineering development of a product. Starting from a tool progression design and the characteristics of the material, the SacmaForm® software offers a simple and intuitive method for calculation of volumes and forging loads, together with other necessary data for evaluating the economics of the project.

WINNING

 TECHNOLOGIES®

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