Quality Heavy Machine Repair

Upsetter & Header repair & rebuilding

Introduction

Since 1972 Campbell Inc. has specialize in forging upsetter repair and rebuilding, forging roll or reducer roll repair and rebuilding and header repair and rebuilding. The name Campbell is well known in the forging and fastener industries for quality, efficiency and productivity in rebuilding forging upsetters and header repair and rebuilding work.   To compete in today’s world market, forging upsetters, rolls and headers need to be in top shape and must maintaining proper tolerances and clearances to produce quality parts.  Forgers also need to take advantage of the latest in technology in order to optimize performance and minimize down time.  Campbell Inc's forging upsetter rebuild team, forging roll repair and rebuilding and header repair and rebuilding teams are up to date on all of the latest improvements in the industry and can provide you with the best options for your forging upsetter rebuild. 

Upsetter Repair & Rebuilding,Header Repair & Rebuilding:

Disassembly & Inspection

A forging upsetter repair or rebuilding or header repair or header rebuilding project at Campbell, Inc. begins with the disassembly, inspection and engineering of the parts and components. Parts are thoroughly cleaned, checked for wear, cracks and dimensional integrity.  An inspection report is provided detailing our findings and calling out anything that may impact the project or cause a change in scope or cost.

Upsetter & Header Repair & Rebuilding: Welding of Parts

Due to the hight cost and low availability of replacement parts repairing damaged or worn forging press parts is a very productive and cost effective idea.  Our upsetter repair work and header repair work involves welding worn, damaged or broken parts.  We are able to perform weld repairs on cast iron, cast steel, forged or fabricated steel parts.  Cracks are cut out and then welded or brazed.   Successful repair welding involves proper preparation, preheat, the selection of welding materials and welding proceedures used is critical as is the stress relieving of the part.  We at Campbell Inc. have refined our steps and procedures over the years to provide the highest quality welding services in the industry for your upsetter repair and rebuild or header repair and rebuilding work. 

Upsetter & Header Repair & Rebuilding: Machining of Parts

Upsetter and header repair involves machining on welded parts, fabricated and cast parts or forged material.  We understanding the proper clearances and tolerances demanded by the different forging presses.  Our engineering staff will work with you on selecting the best materials for the different forging press parts to insure the longevity of the finished components.

Upsetter & Header Repair & Rebuilding: Assembly & Testing

When rebuilding upsetters or headers, or repairing their parts the finished components will first be checked for size and quality before the sub assemblies fit together.  On upsetter and header rebuilds the sub assemblies will then be installed in the frame, adjusted for proper running clearance and operation.  Rebuilt upsetters and headers will be test run in our plant before final customer run off and acceptance.    

Upsetter & Header Repair & Rebuilding: on site machining, welding and millwrighting.

Campbell Inc. can provided skilled technicians to perform upsetter or header maintenance and repair work in your plant.  Our millwrights can travel to your site for trouble shooting, disassembly, repair, adjustment work and assembly.  We will also provide welding work in the field and have welded upsetter frames and header frames in place.  Many are larger upsetters that are very costly to disassemble and ship out for repair.  Portable machining work is also a viable alternative to save on down time or disassembly time.  Campbell Inc. has the ability to perform on site machining of bores and bed surfaces, locate, drill and tap holes in the customer's plant.

Upsetter & Header Repair & Rebuilding:Controls, Lube Systems, Clutches & Upgrades

Upsetter rebuilding will typically include installing new controls, lube systems, pneumatics and some times automation, the same goes for header rebuilding.  Often, rebuilding upsetters and headers that are older will provide a better return on investment than newer machines because of their heavier construction and durability.  A good heavy older machine can be returned to OEM running specifications and then be upgraded with all the latest in controls and operating systems that the new machines have and provide the customer with a great value for their investment. 

Upsetter & Header Repair & Rebuilding:Preventative and predictive maintenance inspection

Upsetter and header preventative and predictive maintenance is more important than ever.  If you hope to compete in a world market, knowing what shape your equipment is in is critical for maximizing uptime.  Campbell, Inc. can provide upsetter preventative maintenance inspections or header preventative maintenance inspections as well as set up and monitor your predictive maintenance programs as well.   Our skilled engineers and field service technicians have the experience to perform a one time, annual, semi annual or quarterly upsetter and header preventative maintenance inspections.   If you are looking to set up your own in house upsetter preventative maintenance inspections or header PM inspections we can help by providing training and assistance.  

Partial list of manufacturers whose equipment we work on.

Ajax, National, Hill Acme, Hatebur, Eumuco, Etchells, Formax, Nedschroef, Waterbury Farrel, Sakamura, Hasenclever, Kieserling, Krematorsk, Asahi Okuma, Nakashimada to name a few.

Photos

Broken frame was welded, stress relieved and machined. 062 Welding Hatebur AMP 20 Frame Shipping AMP 70 slide after repair
Main shaft assembly after repair Some cracks from AMP 20 Hatebur Gear from 10" Upsetter
National Reducer Roll Frame had major cracks that needed welding 005 Broken eccentric shaft
096 Assembly & Fitting 060 Hatebur AMP 20 057 Ashai Header ram
Early stages of assembly Rough forging for new upsetter crank 055 Ashai Header connection
098 New lube system Rebuilt 7" Ajax Cam slide 055 Header ram and pitman
099 Finished reducer roll Knuckle fitting and assembly 088 Rebuilt National threader
National Reducer roll 7" Upsetter parts 086 Installing new lube system on National Threader
National Reducer Roll 3" upsetter parts during inspection 071 Kieserling Upsetter rebuild
8" Ajax disassembled 065 Machining Hatebur crank 058 National cold header ram DSC00005
8" Ajax upsetter 056 Ashai connection with new bushings and wrist pin Repairing cams
Cam slide connection link 056 Machining cold header ram National Reducer Roll finished IMG_6979
019 Coming in for repair work New Lube system
Machining slide after repairs 006 3" upsetter broken toggle slide Repaired
Machining new eccentric shaft

Campbell Inc. can provide you with used forging or metal stamping equipment or assist you in your search.  We work with many of the top machinery dealers and also are aware of under utilized equipment and spare parts that our customers have that may  be available for purchase.  We can also provide the service of inspecting the equipment before you purchase it and provide a quote for repairs, replacement parts, rebuilding or modernizing the equipment to satisfy your needs. 

We work with used metal stamping presses, used forging presses, used hydraulic forging presses, used hammers, used upsetters, used reducer rolls, used open die hammers to name a few.  We work on all major brands of metal stamping presses: Aida, Bliss, Cleanring, Chicago, D&K, Erie, Eumuco, Niagara, Danly, Verson, Erfurt, Schuler, TMP, Voronezh, IWK, Waterbury Farrel, U.S. Baird, Weingarten, British Clearing, Wilkins & Mitchell, IHI, Komatsu, Hitachi, Zosen, Fukui, Fagor, Federal, V&O, L&J, South Bend Johnson, Minster, Steel Weld, Soenen, Toledo, PTC, Eagle, Brown & Boggs, Blow, CMC, Sutherland, Perkins, Havir, Hamilton, Baldwin, Manzoni,  Williams & White, Eumuco.

We work on all makes and models of foring equipment including: Ajax, B&S Massey, Beche, Bliss, Clearing, Danly, Erie, Erfurt,  Etchells, Eumuco, Ficep, FPM,  Hasenclever, Komatsu, Kurimoto, Lasco, Manzoni, Massey, Maxi press, Multiforge, Muller Weingarten, National,  Niagara,  Schuler, Siempelkamp, Smeral, Sumitomo, TMP, Voronezh,  Verson, Viccari,  Zdas, Wilkins & Mitchell,   

517-371-1034
925 River St. Lansing, MI 48912