Russia · 4000T Hot Die Forging Press
Full Acceptance & Performance Verification
A leading Russian commercial-vehicle component forging enterprise conducted systematic acceptance testing on Weirong's VFP-4000 across four dimensions — performance, precision, stability, and safety. Every metric exceeded the contractual standard. The client confirmed full satisfaction and has placed a follow-on order.
Client Overview
A Tier-1 forged-component supplier to Russia's leading commercial-vehicle manufacturers, this enterprise has operated a dedicated hot-forging production line in Russia's Volga automotive belt for over 15 years.
The Challenge
Replacing legacy press tonnage is never trivial. The client came with specific, non-negotiable technical requirements shaped by the demands of high-volume automotive forging in Russia's industrial environment.
Legacy presses delivered inconsistent striking energy across the stroke, causing flash-line variation exceeding ±1.2 mm and elevated scrap rates on crankshaft and steering-knuckle lines. The replacement press needed measurably tighter energy consistency at 4000T nominal.
OEM contracts require dimensional tolerances of ±0.1 mm on critical forging features. Achieving this in continuous production — not just during acceptance trials — demands a press with sub-0.05 mm slide guide parallelism and minimal angular deflection under eccentric loading.
The plant operates three shifts, 330 days per year. Any unplanned downtime on the main press directly halts multiple downstream operations. The new press had to demonstrate sustained reliability in a formal 30-day continuous production trial prior to final acceptance.
All new equipment must comply with Russia's GOST safety standards and EAC technical regulations. The complete safety system — light curtains, hydraulic overload protection, dual-hand control, and emergency stop — had to be formally validated before installation sign-off.
Shipping a 4000T press from China to Central Russia required coordinating rail freight through the Trans-Siberian corridor, customs clearance with EAC documentation, on-site foundation preparation, and installation support from Weirong engineers in under 45 working days.
The plant's maintenance team had no prior experience with modern PLC-controlled forging presses. A complete training programme for operators, maintenance technicians, and automation engineers was required as part of the commissioning scope — fully delivered in Russian.
The Solution — VFP-4000 Hot Die Forging Press
Weirong supplied a complete hot-forging press system comprising the main VFP-4000 press, automated billet feeding unit, hydraulic die-clamping system, centralized lubrication, and a Siemens-based control package — with full commissioning and operator training included.
The VFP-4000 is built on Weirong's four-column prestressed frame architecture — a design that delivers superior angular stiffness and minimal elastic deformation under full eccentric load. The eccentric-gear main drive, combined with a high-inertia flywheel, ensures consistent striking energy per stroke regardless of billet temperature or die position variation.
For this project, Weirong adapted the standard VFP-4000 configuration to the client's specific requirements: the main motor was upgraded to 450 kW with an integrated frequency converter for precise SPM control, the PLC programme included Russian-language HMI localisation, and the hydraulic overload protection threshold was pre-set to the customer's die-protection specifications. The complete package was factory-acceptance-tested in Weirong's own facility before shipment.
| Model | VFP-40000 |
| Nominal Force | 40,000 kN (4,000T) |
| Stroke | 400 mm |
| Strokes / Min | 16 – 25 SPM (VFD) |
| Die Height (Closed) | 820 mm |
| Bolster Size | 2,800 × 1,900 mm |
| Main Motor | 450 kW |
| Frame Type | 4-Column Prestressed |
| Slide Guide | 8-Face, 1200 mm Length |
| Drive Type | Eccentric Gear |
| Overload Protection | Hydraulic, PLd-rated |
| Control System | Siemens S7-1500 PLC |
| HMI | 15" Touchscreen (RU / EN) |
| Lubrication | Automatic Centralized |
| Safety | Light Curtain + Dual-Hand |
| Certification | CE / ISO 9001 / EAC Docs |
| Machine Weight | approx. 320 T |
Four-Dimension Acceptance Testing
The client's engineering team, accompanied by a third-party metrology inspector, conducted a structured acceptance programme over 18 working days following commissioning. Tests were executed against a mutually agreed Acceptance Test Plan (ATP) covering four technical dimensions. All 31 ATP line items were passed at first submission.
What Changed After Installation
Comparing the first six months of VFP-4000 production against the decommissioned legacy press baseline, the client's process engineering team recorded the following improvements.
We have purchased forging equipment from European suppliers for twenty years, so our acceptance bar is high. When Weirong's commissioning team proposed a 30-day continuous trial with third-party metrology, we accepted immediately — we did not expect them to be that confident. The VFP-4000 cleared every item in our ATP at first attempt. The parallelism numbers were better than any press we have ever run in this plant. Zero unplanned stops in 720 hours is something our legacy presses never achieved in their entire service life. Our board has already approved a purchase order for the second unit.
From Contract to Accepted Production — 7 Months
The entire project, from contract signature to formal acceptance certificate, was completed within the agreed schedule of 28 weeks.
Contract signed. Weirong application engineers conducted a remote technical workshop with the client's process and installation teams to confirm ATP scope, power supply specifications (10 kV, 50 Hz), foundation loadings, and Russian-language HMI requirements. Engineering freeze confirmed at end of Week 2.
Main press manufacturing at Weirong's Zhejiang facility with biweekly video progress reports to the client. Week 12: client sent two engineers to Zhejiang for Factory Acceptance Test (FAT) — press run at full load for 8 hours, all ATP items verified at factory level. FAT certificate signed.
Press disassembled into 14 major shipping units and transported by ocean freight to Vladivostok, then rail freight to the plant's rail siding. Weirong provided complete EAC technical documentation package for Russian customs clearance. All units arrived within the 4-week shipping window.
Weirong dispatched a three-person installation team (mechanical lead, electrical engineer, controls specialist). Foundation anchor bolts installed and grouted per Weirong's drawings. Press assembly, alignment, electrical panel connection, and hydraulic system commissioning completed over 4 weeks.
Press commissioned under dry-run (no tooling) conditions. All safety interlocks verified. 5-day operator training programme delivered in Russian: 12 press operators trained on HMI, die-change procedure, and routine maintenance. Maintenance manual and spare-parts list handed over.
18-day formal ATP programme executed across 4 dimensions (Performance, Precision, Stability/Durability, Safety). Third-party metrology inspector engaged by client. 30-day continuous production trial completed at 96.4% OEE. Formal Acceptance Certificate co-signed by client Chief Engineer and Weirong commissioning lead.
Russia · 4000T Hot Die Forging Press
Full Acceptance & Performance Verification
A leading Russian commercial-vehicle component forging enterprise conducted systematic acceptance testing on Weirong's VFP-4000 across four dimensions — performance, precision, stability, and safety. Every metric exceeded the contractual standard. The client confirmed full satisfaction and has placed a follow-on order.
Client Overview
A Tier-1 forged-component supplier to Russia's leading commercial-vehicle manufacturers, this enterprise has operated a dedicated hot-forging production line in Russia's Volga automotive belt for over 15 years.
The Challenge
Replacing legacy press tonnage is never trivial. The client came with specific, non-negotiable technical requirements shaped by the demands of high-volume automotive forging in Russia's industrial environment.
Legacy presses delivered inconsistent striking energy across the stroke, causing flash-line variation exceeding ±1.2 mm and elevated scrap rates on crankshaft and steering-knuckle lines. The replacement press needed measurably tighter energy consistency at 4000T nominal.
OEM contracts require dimensional tolerances of ±0.1 mm on critical forging features. Achieving this in continuous production — not just during acceptance trials — demands a press with sub-0.05 mm slide guide parallelism and minimal angular deflection under eccentric loading.
The plant operates three shifts, 330 days per year. Any unplanned downtime on the main press directly halts multiple downstream operations. The new press had to demonstrate sustained reliability in a formal 30-day continuous production trial prior to final acceptance.
All new equipment must comply with Russia's GOST safety standards and EAC technical regulations. The complete safety system — light curtains, hydraulic overload protection, dual-hand control, and emergency stop — had to be formally validated before installation sign-off.
Shipping a 4000T press from China to Central Russia required coordinating rail freight through the Trans-Siberian corridor, customs clearance with EAC documentation, on-site foundation preparation, and installation support from Weirong engineers in under 45 working days.
The plant's maintenance team had no prior experience with modern PLC-controlled forging presses. A complete training programme for operators, maintenance technicians, and automation engineers was required as part of the commissioning scope — fully delivered in Russian.
The Solution — VFP-4000 Hot Die Forging Press
Weirong supplied a complete hot-forging press system comprising the main VFP-4000 press, automated billet feeding unit, hydraulic die-clamping system, centralized lubrication, and a Siemens-based control package — with full commissioning and operator training included.
The VFP-4000 is built on Weirong's four-column prestressed frame architecture — a design that delivers superior angular stiffness and minimal elastic deformation under full eccentric load. The eccentric-gear main drive, combined with a high-inertia flywheel, ensures consistent striking energy per stroke regardless of billet temperature or die position variation.
For this project, Weirong adapted the standard VFP-4000 configuration to the client's specific requirements: the main motor was upgraded to 450 kW with an integrated frequency converter for precise SPM control, the PLC programme included Russian-language HMI localisation, and the hydraulic overload protection threshold was pre-set to the customer's die-protection specifications. The complete package was factory-acceptance-tested in Weirong's own facility before shipment.
| Model | VFP-40000 |
| Nominal Force | 40,000 kN (4,000T) |
| Stroke | 400 mm |
| Strokes / Min | 16 – 25 SPM (VFD) |
| Die Height (Closed) | 820 mm |
| Bolster Size | 2,800 × 1,900 mm |
| Main Motor | 450 kW |
| Frame Type | 4-Column Prestressed |
| Slide Guide | 8-Face, 1200 mm Length |
| Drive Type | Eccentric Gear |
| Overload Protection | Hydraulic, PLd-rated |
| Control System | Siemens S7-1500 PLC |
| HMI | 15" Touchscreen (RU / EN) |
| Lubrication | Automatic Centralized |
| Safety | Light Curtain + Dual-Hand |
| Certification | CE / ISO 9001 / EAC Docs |
| Machine Weight | approx. 320 T |
Four-Dimension Acceptance Testing
The client's engineering team, accompanied by a third-party metrology inspector, conducted a structured acceptance programme over 18 working days following commissioning. Tests were executed against a mutually agreed Acceptance Test Plan (ATP) covering four technical dimensions. All 31 ATP line items were passed at first submission.
What Changed After Installation
Comparing the first six months of VFP-4000 production against the decommissioned legacy press baseline, the client's process engineering team recorded the following improvements.
We have purchased forging equipment from European suppliers for twenty years, so our acceptance bar is high. When Weirong's commissioning team proposed a 30-day continuous trial with third-party metrology, we accepted immediately — we did not expect them to be that confident. The VFP-4000 cleared every item in our ATP at first attempt. The parallelism numbers were better than any press we have ever run in this plant. Zero unplanned stops in 720 hours is something our legacy presses never achieved in their entire service life. Our board has already approved a purchase order for the second unit.
From Contract to Accepted Production — 7 Months
The entire project, from contract signature to formal acceptance certificate, was completed within the agreed schedule of 28 weeks.
Contract signed. Weirong application engineers conducted a remote technical workshop with the client's process and installation teams to confirm ATP scope, power supply specifications (10 kV, 50 Hz), foundation loadings, and Russian-language HMI requirements. Engineering freeze confirmed at end of Week 2.
Main press manufacturing at Weirong's Zhejiang facility with biweekly video progress reports to the client. Week 12: client sent two engineers to Zhejiang for Factory Acceptance Test (FAT) — press run at full load for 8 hours, all ATP items verified at factory level. FAT certificate signed.
Press disassembled into 14 major shipping units and transported by ocean freight to Vladivostok, then rail freight to the plant's rail siding. Weirong provided complete EAC technical documentation package for Russian customs clearance. All units arrived within the 4-week shipping window.
Weirong dispatched a three-person installation team (mechanical lead, electrical engineer, controls specialist). Foundation anchor bolts installed and grouted per Weirong's drawings. Press assembly, alignment, electrical panel connection, and hydraulic system commissioning completed over 4 weeks.
Press commissioned under dry-run (no tooling) conditions. All safety interlocks verified. 5-day operator training programme delivered in Russian: 12 press operators trained on HMI, die-change procedure, and routine maintenance. Maintenance manual and spare-parts list handed over.
18-day formal ATP programme executed across 4 dimensions (Performance, Precision, Stability/Durability, Safety). Third-party metrology inspector engaged by client. 30-day continuous production trial completed at 96.4% OEE. Formal Acceptance Certificate co-signed by client Chief Engineer and Weirong commissioning lead.