Metal Forming
Built Strong: Hydraulic Cylinders for Metal Forming
The sheet metal industry relies on advanced machinery to transform raw materials into high-precision components for construction, automotive, and industrial applications. Achieving complex geometries and tight tolerances in metal forming requires robust hydraulic power and control. Toleng Hydraulics provides customized hydraulic solutions engineered to meet the rigorous demands of this dynamic sector.
In sheet metal fabrication, modern equipment achieves peak performance and efficiency through precision automation. Our hydraulic cylinders are ideal for a wide range of metal forming machines, including bending machines, stamping presses, and shearing equipment. Toleng Hydraulics supplies high-force cylinders and rotary joints for bending machine systems, extruder presses, and forging presses, currently capable of supporting machinery used in large-scale industrial operations to cope with the extreme forces encountered during heavy plate forming and high-speed production cycles.
Toleng Hydraulics also develops and manufactures specialized hydraulic cylinders and hydraulic units for complementary equipment such as coil handling systems, straightening machines, and transfer feeders, further enhancing its business portfolio in this growing industry.
- Custom-engineered hydraulic cylinders for bending, extrusion, and forging applications, including main press cylinders, die cushion cylinders, clamp cylinders, and ejector cylinders designed for high-cycle, high-tonnage operations
- Precision synchronization and position control systems for multi-cylinder applications in bending machine systems and large press brakes, ensuring accurate angle formation and repeatable part quality
- High-pressure cylinder designs capable of sustaining extreme forging loads, featuring advanced sealing technologies to withstand shock loads, thermal exposure, and contamination from scale and process fluids
- Hydraulic cylinders for auxiliary and material handling functions within sheet metal stamping lines and extruder presses, including coil car lift cylinders, transfer feeder cylinders, and straightener rolls positioning cylinders
- Integrated end position damping and proximity sensing solutions enabling smooth deceleration at stroke ends and real-time position feedback for automated press cycles and Industry 4.0 integration
- Surface treatment and protective coating options tailored to the metal forming environment, including hard chrome plating, zinc-nickel coatings, and painting according to customer specifications for corrosion resistance against coolants and hydraulic fluids
References + Applications
Customized hydraulic cylinders for automated stamping line
Modern automated stamping lines must perform with split-second precision and unwavering reliability under some of the most punishing manufacturing conditions on earth: repetitive shock loads, high-speed cycling, extreme side forces, and continuous 24/7 operation. During a high-volume production run at an automotive manufacturing plant, a fully automated stamping line was deployed to produce thousands of body panels and structural components per shift. These presses operated continuously, processing high-strength steel and aluminum sheets with micron-level accuracy. Toleng Hydraulics provided a series of custom-engineered cylinders for these stamping applications, including die cushion cylinders, blank holder cylinders, sliding bolster cylinders, and counterbalance cylinders.
Die Cushion Cylinder (Deep Draw Press):
Piston Diameter: 200 mm
Piston Rod Diameter: 140 mm
Stroke: 400 mm
Working Pressure: 25 MPa
Function: Provides controlled counterforce during deep drawing operations, ensuring wrinkle-free forming of complex automotive body panels.
Blank Holder Cylinder (Transfer Press):
Piston Diameter: 160 mm
Piston Rod Diameter: 110 mm
Stroke: 250 mm
Working Pressure: 23 MPa
Function: Secures sheet metal blank during the stamping process with precisely controlled clamping force to prevent material slippage.
Sliding Bolster Cylinder (Die Change System):
Piston Diameter: 100 mm
Piston Rod Diameter: 70 mm
Stroke: 6,500 mm
Working Pressure: 20 MPa
Function: Moves heavy die sets (up to 60 tons) in and out of the press area, enabling rapid tooling changeovers in under five minutes.
Counterbalance Cylinder (Press Ram):
Piston Diameter: 180 mm
Piston Rod Diameter: 125 mm
Stroke: 600 mm
Working Pressure: 24 MPa
Function: Compensates for ram weight and maintains precise positional control during high-speed stamping cycles up to 30 strokes per minute.
Piloted Check Valve Cylinder (Safety Lock):
Piston Diameter: 80 mm
Piston Rod Diameter: 55 mm
Stroke: 150 mm
Working Pressure: 25 MPa
Function: Locks press components in position during maintenance or emergency stops, ensuring operator safety and preventing unintended movement.
Technical Highlights:
The large-bore die cushion cylinders on heavy-duty stamping presses are engineered to withstand extreme cyclic loads during high-volume production. Operating at up to 25 MPa, they generate holding forces exceeding 300 kN, enabling consistent forming of advanced high-strength steel alloys while maintaining dimensional accuracy within ±0.1 mm.
All cylinders feature heavy-duty guide rings and wear-resistant bearings designed to handle off-center loading and repetitive impact forces, while maintaining leak-free performance in temperatures ranging from 10°C to 80°C during continuous operation.
Integrated magnetostrictive displacement sensors provide real-time position feedback with ±0.05 mm accuracy, enabling closed-loop servo control for critical applications such as draw depth regulation and dynamic cushion force profiling during high-speed stamping operations.
Some of our Applications
Bending Machine System
Extruder Presses
Forging Presses
Sheet metal industry