D&S Machine Repair

Stamping & Repair Services | Hastings, MI

(269) 948-9122

800-Ton Danly Rebuild

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Our team completely rebuilt this 800-ton Danly 4-point stamping press. We disassembled, cleaned, and inspected each press component to ensure proper repairs were made. We manufactured new tie rod nuts, adjustment nuts, worm gears, worm shafts, slide adjust bearing retainers, slide adjust shafts, and eccentric pins.

Our Machinists machined the bed, bolster and slide flat and parallel, and repaired the damaged T-slots in the slide face and bolster face to allow proper die connection. Our welders repaired cracks in the slide, and eccentric gears.

Our Engineers designed a new metered lubrication system utilizing the existing reservoir and drainage systems and worked with outside contractors to install the press pit, support frame and floor plating.

Our technicians installed new divider valves, lubrication lines and hoses, as well as a new recirculating pump, filters, gauges, and cycle switches.  Our electricians stripped out the old wiring and wired new control panels with PLC programed to work with the new metered lubrication system and upgraded the motor, brake monitor, and tonnage monitor. Our team assisted in assembling the press and leveling the press and performed tests to ensure the press and all safety systems were running properly.

Crown Before Repairs
Crown Before Repairs
Crown After Repairs
Crown After Repairs
Crown After Repairs
Electrical Panel Before Repairs
Electrical Panel After Repairs
Electrical Panel After Repairs
Slide Before Repairs
Slide Before Repairs
Slide After Repairs
Slide After Repairs
Bolster Before Repairs
Bolster Before Repairs
Bolster After Repairs
Bolster After Repairs

 

Slide Screw Repair

Slide Before
Slide Complete
Slide Complete 2

Our customer had two slide adjust nuts suffer catastrophic failure when they broke in half during production. When our team pulled the slide out, they found the threads from the nuts had sheared off and wrapped around the screws and in the nut housing. The screws had damage to the threads and metal shavings and oil had collected in the housing. Our team inspected the rest of the press and found the damage was contained to the slide adjustment components.

With the slide back at our facility we were able to manufacture four new adjustment screws and four new adjustment nuts. Additionally, our team cleaned out and repainted the slide adjustment barrels, cleaned, and repainted the inside of the slide, replaced the worm gears and worm shafts, machined the bottom of the slide flat, and reassembled the adjustment components back into the slide. Once all work was complete, we transported the slide back to our customer’s facility and installed the slide back into the press.

Broken Adjustment Nut
Broken Adjustment Nut
New Adjustment Nut and Screw
New Adjustment Nut and Screw
New Worm Gear and Screw and cleaned Housing.
New Worm Gear and Screw and cleaned Housing.

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300 Ton Minster Slide Repair

KODAK Digital Still Camera
300 ton Minster Slide 2

Our customers slide adjust screws on this Minster slide wouldn’t turn due to rust that had formed on the screws, nuts, worm shafts, worm bearings, and barrel housings, from water-based die lube that was in the lubrication system.

Our team was able to disassemble the slide adjust assembly without causing damage to the adjustment nuts, worm shafts, worm bearings, barrel housings, or adjustment screws. Our team inspected each component for cracks and wear, cleaned, and polished all the slide adjust components to proper operating condition.

We machined the slide back flat, parallel, and square to OEM specifications. We replaced the customers’ contaminated oil, filters, damaged lube lines, lube orifices, installed new proper oil, gave the slide a fresh paint job, rebuilt and installed the slide, set the gibs to proper run clearances and test ran the press to ensure proper and safe operation.

All work was completed within 3 weeks.

Rusted Adjustment Screw
Rusted Adjustment Screw
Polished Adjustment Screws
Polished Adjustment Screws
Rusted Worm Shaft
Rusted Worm Shaft
Polished Worm Shaft
Polished Worm Shaft

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Bullet Machine Repair

bullet press before
bullet press after

We received this machine from the Army. The machine is specialized to make .50 caliber jacketed projectiles for the Army. This machine came to us from their on base storage facility. The machine had not been used for production in decades. Many of the functioning components for the feed and transfer systems had been scavenged from this machine over the years to keep other machines operational. Our customer wanted this machine completely rebuilt and updated with the latest technology so that they could increase production from this machine. The machine was totally disassembled. All painted components were sand blasted to remove all existing paint. The components were then all inspected and machined to OEM specifications. The crank shaft was straightened and polished; slide and frame were bored and milled to ensure parallelism. We engineered and installed an Ortlinghaus clutch conversion for this press to replace the full revolution mechanical clutch. Air counterbalance cylinders were also added to this machine to reduce press wear and increase stopping time.

We also designed and installed an Allen-Bradley Clutch/brake control kit. The Rockwell Clutch/Brake Control system used on this press is a DC version with customized code written specifically for D&S Machine Repair, Inc. It utilizes two independent MicroLogix1500 processors. Both controllers monitor all clutch/brake I/O and exchange information about machine status via hard wire I/O. Both processors independently generate operator prompts and machine faults which are displayed on the Panel View 600 Prompts & Faults Screen.

All of these features we added allowed our customer to increase production speeds while also incorporating a much higher level of die protection.

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1500 Ton Automotive Stamping Press

1500 ton bliss automotive stamping press

Problem

With the boom in the auto industry, a customer of ours at D&S Machine Repair, Inc. was producing very large volumes of high strength and ultra-high strength steel components, which was putting heavy strain on their 1500 ton Bliss press. Over time, the original cast iron slide developed persistent cracks in an area that had already been braze-repaired on several occasions, and the wrist pocket became so damaged it could no longer hold oil.

Solution

Our technicians cleaned, inspected, and took detailed measurements of the existing slide to reverse engineer a 3D model and create a detailed list of all the components. After a diagnostic evaluation, we engineered several upgrades to the original design that would provide greater strength and stability while improving the slide’s functionality. By shortening the knockout hole we could increase the material thickness under the wrist pocket to avoid future damage. Increasing the thickness of the slide face would extend its wear life, while adding T-slots would serve to facilitate die fastening and speed changeover.

Inside our shop, we used a full range of fabrication capabilities to execute the repairs and improvements. In addition to plasma cutting cast iron and steel plate, we machined the new and replacement components, ground them to OEM tolerances, and made precision weld repairs to restore the worn areas. A fresh coat of paint made the press look new. Numerous dimensional and visual inspections throughout each of the many processes ensured that we upheld close ±0.001″ tolerances on all on this large cast iron press slide, which featured dimensions of 41.0″ in width x 34″ in depth x 60.50″ in height.

Within a six week time frame, the press was back on their factory floor operating at full capacity. Our solid understanding of stamping press technology combined with our expert fabrication and repair skills allowed the customer to improve their throughput and gain extended value from their expensive capital equipment.

To learn more about this project or the engineering and fabrication processes we used to refurbish it, contact us today.

Capabilities Applied/Processes

Primary:

  • Reverse Engineering
  • Engineering Modeling – Redesign/ Upgrade
  • Machining
  • Milling
  • Boring
  • Drilling
  • Grinding
  • Welding
  • Flame/Plasma Cutting

Secondary:

  • Painting

Overall Part Dimensions

  • Height: 60.50″
  • Depth: 34.00″
  • Width: 41.00″

Tightest Tolerances

  • 0.001

Material Used

  • Steel

Material Stamped

  • High-Strength and Ultra-high Strength Steel

In-Process Testing/Inspection Performed

  • Dimensional Inspection
  • Visual Inspection

Industry for Use

  • Automotive Stamping

Volume

  • 1

Delivery/Turnaround Time

  • 6 weeks

Standards Met

  • Customer Specifications
  • CAD Drawing

Product Name

  • 1500 Ton Slide

Other Projects

Minster Knuckle Joint Press

minister knuckle joint press yield strength

We provided servicemen, equipment and trucking to load this Minster Knuckle Joint Press and transport it to our facility. The machine was completely disassembled, cleaned and inspected. The customer wanted to increase the shut height of the press and widen the die space area. We completed a stress analysis to determine the maximum modifications that could be safely made, uprights were then modified from a 34 to 38 inch clear span between uprights for 15 3/8 inches above bolster face.

We removed enough material from the upright to allow a 37 inch wide slide plate clearance during the entire press stroke and adjustment. We manufactured a T-slotted bolster with die lifter slots to match their existing tooling. Increased the slide face flange to 37 L/R x 36 F/B inches and cut standard ¾ inch T-slots into the slide adapter face. We lengthened the existing counterbalance rod to accommodate the modified shut height adjustment. We provided the material and engineering to design an electrically powered wedge adjustment mechanism that replaced the manual adjustment. The original control was stripped off the press control and replaced with a Link 5000 control. We also calibrated the tonnage monitor and tested the linear tracking in our facility. The press was assembled in our facility where we replaced, troubleshot and tested the lubrication, control, and pneumatic systems to ensure proper operation. We transported the press to our customer\’s facility in Nebraska and rigged it into place and integrated the press to the feed line.

minister knuckle joint press before
minister knuckle joint press after

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