FIBRO 2480.019.03000.1: Engineering Solution for Increasing the Durability of Gas Springs in Press Equipment

Introduction: Minimizing Downtime in Press Production

The efficiency of industrial press operations is critically dependent on the reliability and durability of key equipment components. Gas springs, providing constant pressure and return force, are an integral part of many dies and molds. However, their operation is often accompanied by challenges related to premature wear. The main reason is the action of transverse forces and uneven loads, which arise due to non-ideal centering or displacement of moving parts of the mold. This leads to intense friction of the spring rod against the guides, deformation of the internal seals and, as a result, loss of gas pressure and complete failure of the spring.

Such failures inevitably cause unplanned equipment downtime, which directly affects production volumes, increases maintenance and repair costs, and increases operational risks. In modern Ukrainian industrial production, oriented to DSTU and EN standards, ensuring continuous operation and minimizing downtime is a key priority. A solution that allows you to significantly extend the service life of gas springs and increase the stability of the press equipment is the use of specialized load distribution elements. The FIBRO 2480.019.03000.1 Hardened Backing Plate is designed specifically to address these engineering challenges.

Technical Characteristics: Support Plate FIBRO 2480.019.03000.1

The FIBRO 2480.019.03000.1 support plate is a high-precision component designed to optimize the operation of gas springs and press equipment. Below are the detailed specifications.

Principles of Operation: Load Distribution, Friction Reduction and Mechanical Stability

The key principle of the operation of the FIBRO 2480.019.03000.1 support plate is the effective distribution of the axial load and the prevention of destructive transverse forces on the rod and the gas spring body. In typical press operations, especially with long strokes or the use of asymmetric dies, the center of load can shift relative to the axis of the gas spring rod. This creates a moment of force that tends to bend the rod and causes intense friction between the rod and the spring guide sleeve, and between the spring body and the bearing surface of the tool. Such conditions lead to accelerated wear, increased heat generation and premature failure, which is unacceptable in high-performance production cycles.

The hardened FIBRO support plate is installed between the end of the gas spring and the corresponding part of the mold. It acts as an intermediate element with high mechanical stability. Thanks to the use of special tool steel (1.2842 or 1.2379) with a hardness of more than 58 HRC, the plate withstands the intense contact stresses that occur during the compression of the gas spring. A precisely machined surface with low roughness (Ra < 0.4 μm) provides a minimal coefficient of sliding friction, which is critical for absorbing lateral load components without significant energy loss or wear.

The function of the plate is to create a stable, flat bearing surface that accepts all the displaced loads while providing free but controlled sliding. This prevents direct contact of the rod or spring body with the components of the equipment at an angle, which eliminates point wear and deformation. Under dynamic load conditions, when the force of the press can reach hundreds of kilonewtons, the ability of the plate to evenly distribute pressure over a large area is key.

The reduction of transverse loads can be described through the mechanics of materials. If a transverse force $F_p$ acts on the stem of a gas spring at a distance $L$ from the support point, it creates a bending moment $M_z = F_p \ imes L$. This moment causes a bending stress $\\sigma_z = M_z \ imes y / I$, where $y$ is the distance from the neutral axis, and $I$ is the moment of inertia of the cross section of the rod. The FIBRO 2480.019.03000.1 support plate, working as a buffer and sliding plane, minimizes $F_p$ and distributes its impact over a larger area. This significantly reduces the stress concentration in the spring rod, preventing its fatigue and destruction. In addition, the reduction of friction $\\mu$ between the moving surfaces of the plate and the spring leads to less heat release $Q = \\mu \ imes N \ imes v$ (where $N$ is the normal force, $v$ is the sliding speed) and slows down material wear.

The use of the plate allows the gas spring to work in conditions as close as possible to ideal axial compression, ensuring the resource declared by the manufacturer and the stability of force parameters throughout the entire operating cycle. This is critical for industries operating according to Industry 4.0 principles, where each component of the system must provide predictable and controlled behavior.

Fields of Application: Optimization of Processes in Ukrainian Industrial Production and Compliance with Standards

The FIBRO 2480.019.03000.1 support plate is used in a wide range of industrial processes where gas springs are used to provide controlled force. Its use is critically important for increasing the reliability and durability of equipment under conditions of intensive operation in the Ukrainian industrial sector. The following are typical application scenarios and their compliance with key standards:

1. Metal Stamping and Drawing: In stamping processes, especially in deep drawing, gas springs are used to press the workpiece and provide stable pressure on the retainer. Asymmetric contours of parts or high travel speeds can cause significant transverse loads on the springs, reaching 10-20% of the nominal spring force (for example, for a spring with a force of 25 kN, the lateral load can be 2.5-5 kN). The FIBRO backing plate protects the springs from these forces, preventing deformation of the tool and guaranteeing the dimensional accuracy of the final product. This meets the requirements of DSTU EN ISO 1602:2018 for molds and ensures compliance of the final product with the requirements of DSTU ISO 2768-1:2006 for dimensional tolerances.
2. Lithuania under Pressure and Lithuania Plastmas: In molds for casting, gas springs are often used to push out finished parts or to create a down force. Thermal expansion of materials (for example, steel molds operating at +180°C - +250°C) and cyclic loads can lead to displacement of mold elements. The support plate stabilizes the operation of the springs, extending their service life and ensuring uninterrupted removal of products without damage. This is critical for ensuring the quality of products certified by UkrSEPRO.
3. Hydraulic Presses and Molding Equipment: In large molding equipment where gas springs are used as compensators or support elements, transverse loads can be particularly significant due to the size and mass of the moving parts. The hardened FIBRO plate guarantees the protection of the springs from mechanical damage and ensures the stability of the system, which has a direct impact on compliance with the safety requirements of DSTU EN 693:2017 (hydraulic presses) and DSTU EN 13736:2016 (mechanical presses).
4. Automated Lines and Conductive Equipment: On highly automated production lines where speed and accuracy are a priority (eg 30-60 cycles/min), any component failure causes the entire line to stop. The integration of FIBRO support plates in the conductor equipment using gas springs increases the overall reliability of the system, reducing the risks of unplanned stoppages and maintaining a high production rate. This ensures the stability of processes monitored by Condition Monitoring systems within the Industry 4.0 concept.
5. Specialized Sheet Metal Processing Tools: When using multi-position dies or when working with sheet metal of a complex configuration, gas springs are subjected to multidirectional loads. The use of a FIBRO support plate in such tools is an effective strategy for preserving the geometry of the tool and ensuring the durability of all its components, which is critically important for productions that have CE and UkrSEPRO certification.

Maintenance and Life Cycle: Increasing the Life of Gas Springs

The integration of the FIBRO 2480.019.03000.1 support plate into the press equipment directly affects the mean time to failure (MTBF) of the gas springs and the overall maintainability of the system. According to empirical data and experience in heavy industry, the use of such plates can increase the MTBF of gas springs by 25-40%, depending on the intensity of the loads and the cyclical operation. This is due to a significant reduction in mechanical wear caused by transverse forces, which allows the springs to work up to their full design life, which can reach 1-2 million cycles.

Typical Failure Modes of Gas Springs (without support plate):

• Rod wear and damage: Direct contact of the rod with the guide elements at an angle leads to rapid abrasive wear, the appearance of grooves and microcracks. These damages can be up to 0.1-0.2 mm deep already after several tens of thousands of cycles.
• Disruption of seals: Lateral loads deform the rod, which causes the destruction of internal seals and leakage of gas (nitrogen). A typical leak can be 0.5-2% of pressure per year under normal conditions, but with increased friction and deformation, this figure increases sharply to 5-10% per month, leading to a rapid loss of efficiency.
• Corrosion and pollution: Damaged seals create conditions for the penetration of external pollution and moisture into the unit, which accelerates corrosion processes, especially in conditions of high humidity or the presence of aggressive environments.
• Зміна характеристик сили: Деградація пружини призводить до нерівномірної сили, що негативно впливає на якість штампування, може спричинити брак продукції та вимагає частих регулювань або заміни. A 10% reduction in power can already be critical for some processes.
• Destruction of internal components: In extreme cases, excessive lateral loads can lead to mechanical destruction of the internal guide elements or the spring rod, causing a complete shutdown of the equipment.

Preventive Maintenance with FIBRO Bearing Plates:

Although the FIBRO 2480.019.03000.1 support plate is a passive component, its presence simplifies and optimizes the preventive maintenance schedule. The following measures are recommended, contributing to the maximum use of the potential of the component and increasing the overall efficiency of the MRO:

• Visual inspection (daily/shift): Check for visible damage, cracks, chips on the plate surface and signs of excessive friction or burrs. Particular attention should be paid to the change in the color of the metal, which may indicate overheating.
• Fixing check (weekly): Control of reliability of tightening of fasteners that fix the plate. The operating temperature can vary from +20°C to +80°C, which requires attention to thermal expansion and possible loosening of the fastener. The recommended tightening torque should be found in the appropriate technical documentation for the fastener.
• Cleaning of work surfaces (monthly or as needed): Removal of accumulated dirt, metal shavings or grease residues that can affect sliding and lead to abrasive wear. Use only cleaning agents recommended by the manufacturer.
• Thickness measurement (every 6-12 months): Control of plate material wear using a micrometer. A significant decrease in thickness (for example, more than 0.5 mm) may indicate critical loads or the need for replacement. Allowable wear is established in accordance with the manufacturer's recommendations.
• Verification of parallelism and concentricity (every 12 months): Using high-precision tools (micrometers, indicator heads) to check the accuracy of the installation of the plate and its parallelism to the support surface. Deviation should not exceed 0.02 mm to ensure optimal load distribution.

Systematic maintenance and control of the condition of the support plate allows timely detection of potential problems and prevention of costly failures of gas springs, ensuring a high level of equipment availability in accordance with ISO 9001 series standards and CE and UkrSEPRO requirements.

Comparison with Alternative Solutions

When selecting components for press equipment, engineers are faced with the need to balance initial investment and long-term operational efficiency. Consider a comparison of the specialized support plate FIBRO 2480.019.03000.1 with two main alternatives: no specialized plate and the use of a universal hardened washer.

Based on the analysis, the use of a specialized support plate FIBRO 2480.019.03000.1 is a technically and economically justified solution to ensure stable and long-lasting operation of press equipment in Ukrainian industrial conditions, investing in reliability and predictability of production.

Compliance with Standards: Ensuring Quality and Reliability

Products used in Ukrainian industry must meet national and international quality and safety standards. The support plate FIBRO 2480.019.03000.1, as an integral component of press equipment, fits into the system of regulatory requirements that ensure its reliable and safe operation. Below is a list of key standards relevant to this type of product and its application:

• DSTU EN ISO 9001:2018 (ISO 9001:2015, IDT): Quality management systems. Requirements This standard establishes general requirements for quality management systems applicable to manufacturers of components such as FIBRO, guaranteeing the consistency of production processes and conformity of products to the declared characteristics.
• DSTU EN ISO 1602:2018 (ISO 1602:2017, IDT): Molds for injection molding. Injection mold components and accessories. This standard applies to mold components, which include gas springs and their accessories, including support plates. It establishes requirements for interchangeability and dimensions, which is critical for the unification of components in mechanical engineering.
• DSTU EN 13736:2016 (EN 13736:2012, IDT): Machine safety. Presses. Safety requirements for mechanical presses. Although the plate is only a component, its reliability directly affects the safety of the entire press covered by this standard. Spring failure due to wear can cause uncontrolled movement of elements, creating risks for operators.
• DSTU EN ISO 4957:2015 (ISO 4957:2013, IDT): Tool steels. This standard defines the requirements for the chemical composition and mechanical properties of tool steels, such as 1.2842 or 1.2379, from which the support plate is made, ensuring its high hardness, wear resistance and stability under dynamic loads.
• Directive 2006/42/EC (Machinery Directive) and the Technical Regulation of Machine Safety (PCMU of January 30, 2013 No. 62): These documents establish essential safety and health requirements for machines and their components. Compliance with them is mandatory for manufacturers of equipment that uses components such as FIBRO plates, and is confirmed by CE marking for the European market and UkrSEPRO certification for the Ukrainian market.

The use of components that meet these standards is a guarantee of reliability, safety and efficiency of production processes, which is critically important for Ukrainian enterprises that seek integration into the European market and increase their own competitiveness, ensuring compliance with the requirements of modern industrial production.

Conclusion: Investment in Reliability and Durability

The support plate FIBRO 2480.019.03000.1 is not just an accessory, but a critically important engineering solution that provides a significant extension of the service life of gas springs in press equipment. Its use allows you to minimize the impact of side loads, reduce friction and wear, prevent unplanned downtime and, as a result, optimize production operating costs. High-quality materials and precise processing, in accordance with international and national standards, such as DSTU and EN ISO, guarantee stable and safe operation in conditions of intensive industrial operation. In the Ukrainian industrial sector, where efficiency and reliability are key success factors, such components play a crucial role in maintaining the continuity of production processes and increasing the competitiveness of enterprises, which corresponds to the spirit and requirements of Industry 4.0.

For more information and a complete range of solutions for press equipment, please visit the UNITEC-D E-Catalog.

List of Used Sources

• FIBRO GmbH. Technical documentation and product catalogs for gas springs and accessories. Available at: www.fibro.com
• PARTcommunity by CADENAS. Technical data and 3D models of FIBRO components. Available at: www.partcommunity.com
• State enterprise "Ukrainian Research and Training Center for Standardization, Certification and Quality Problems" (SE "UkrNDNC"). The official resource with information about national standards of DSTU. Available at: uas.gov.ua
• International Organization for Standardization (ISO). Official site. Available at: www.iso.org