DIES | SHEET METAL FORMING | DISHED HEADS FOR TANKS

Via Monte Corno, 10 | San Giovanni Lupatoto (Verona, Italy)

Tel. +39 045 8778602 | e-mail: [email protected]

www.metalpress.it

D I E S | S H E E T M E T A L F O R M I N G |

D I S H E D H E A D S F O R T A N K S

RENEWAL = expertise + continuous improvement of the process + innovation

ED

. 10

/18

The best way to predict your future is to create it.Abraham Lincoln

Drawing, figures and descriptions contained in this catalogue are only indicativeand do not bind the Manufacturer in any way.

Metalpress, established in 1961, is a subcontracting company working in the field of formed metal components – including complex ones – produced in accordance with customer requirements.Metalpress is specialized in the production of both standard and personalized dished heads for boilers and tanks. Metalpress can meet any forming needs, offering an industrialization consultancy that can improve any kind of

product. Thanks to its vast experience and to a wide range of case histories collected over the years, the Metalpress technical team is able to analyze the feasibility of any kind of pressed products. In addition, its background stemming from various business sectors makes it possible for Metalpress to apply technologies and technical know-how coming from different fields.

THE COMPANY

1961 1978 1984 2017

1961Tornaghi and Cipriani founded the company

1978The production

moved to a 11.000 sq.mt factory area

2017 Metalpress

became a Joint-Stock

Company

1984The company

changed its name to Metalpress

2

11.000 sq.mts total

400 sq.mts of office

50 workers

10 mln € 2017 turnover

4.000 sq.mts of production

1.500 sq.mts of warehouse

THE ORGANIZATION

OUR MANAGEMENT

4I

5M

CO DESIGN

INNOVATION | INTERNATIONALIZATION | INDUSTRIALIZATION | INTEGRATION

MACHINE | MANAGEMENT | METHOD | MEN | MATERIAL

OF PRODUCT | OF PROCESS

Innovation has been the key factor that Metalpress has applied to develop its business, investing in new technologies and trying to adopt the most advanced organizational and production methods.

Streamlined production, inventory optimization, product and process innovation have always been the guidelines that have enabled Metalpress to develop an efficient production system, guaranteeing quality and service to their customers.

INDUSTRIAL TECHNOLOGY

The industrial production of Metalpress are metal forming, drawing and deep drawing, which are carried out by using 4-phase mechanical and hydraulic presses. Metalpress does not follow standard techniques because it chooses the best suited process to meet the customer’s requirements.

For instance: Hydraulic pressing | Drawing Mechanical pressing MIG robotized welding MAG | TIG HD plasma cutting Washing with solvents and ultrasounds

The sheet processing involves the use of: Hydraulic presses from 100 to 1200 tons Mechanical presses from 50 to 600 tons Welding robot

Edge beading and trimming machines

The mechanical and hydraulic presses are driven by robots.

In line with the customer’s requirements, the Metalpress technical team manages surface finishes and carries out the surface treatment of parts and assemblies.

4

RAW MATERIAL

Carbon Steel Stainless Steel Galvanized Steel Duplex Steel and Super Duplex Coated and Prepainted Steel Aluminium and Alloys Brass Copper

Thickness min. 0,9 mm | max. 6,5 mm

Diameters min. 130 mm | max. 1250 mm

Other stamped parts Max width: 1500 mm Max length: 2500 mm

OUR METHODOLOGIES

5S

TPM

SEIRI – SEPARATE | SEITON – TIDY | SEISO – CLEAN | SEIKETSU – SYSTEMATIZE | SHITSUKE – SPREAD OR SUPPORT

TOTAL PRODUCTIVE MAINTENANCE | TOTAL PRODUCTIVE MANAGEMENT

SUPPLY CHAIN

KANBAN ELETRONIC

METHOD

8R METHOD

Right material | quality | quantity | place | time |

method | cost | impression

Budget and binding orders: 3 weeks

Non-repetitive orders: 4 weeks

Excluding construction of the die

Orders for multiples of logistic lots agreed with the customer

JIT METHOD

Just in Time

LEAD TIME

CONSIGNEMENT STOCK

PULL LOGIC

DEFINITION & MANAGEMENT

OF LOGISTIC LOTS

6

MARKET

Heating & Ventilation

Pumps

Pressure tanks

Industrial automation

Food & beverage

Bbq

House appliances

Furniture

Industrial vehicles

Glass industry

Oil & gas

Renewable energies

Automotive

Green technology

Tanks

Industrial air handling

Pharmaceutical

Gearboxes

Tire changers

Agricultural / animal

BUSINESS SECTORS

BUSINESS SECTOR TURNOVER

1% Renewable energies

32% Heating & Ventilation

1% Glass industryIndustrial vehicles 1%

Furniture 3%House appliances 3%

Barbecue 4%

Food & beverage 5%

Industrial automation 12%

Pressure tanks 17%

Pumps 17%

1% Oil & gasItaly 49%

export 51%

MARKET

8

SECTORS

| PUMPS | PRESSURE TANKS

| HEATING & VENTILATION

| FOOD & BEVERAGE

| INDUSTRIAL AUTOMATION

| BARBECUE

| TANKS | HOUSE APPLIANCES

| OIL & GAS

| INDUSTRIAL AIR HANDLING

| INDUSTRIAL VEHICLES

| FURNITURE

10

Cleaning/Degreasing

MIG-TIG and electric welding

Centering embossing to improveassembling and welding operations

and material traceability

Flared holes

Several edges range

Excellent circularity and planarity for perfect assembly and welding

operations

Flat area to improve pipes welding

Holes in any position

Varia

ble

heig

ht

DISHED HEADS

Metalpress is highly specialized in producing dished heads. The range offers multiple sizes that are suitable for a variety of sectors (solar thermal power, food and beverage, sanitation and heating etc).

GENERAL INFORMATION

Different thicknesses and heights from those listed in the catalogue can be requested, including the following processes: Flanging Holes by die Holes with robotized plasma cut

Central holes at end of drawing process Electrical spot welding Flared holes

All dished heads are produced according to the standards currently in force.

FLARED HOLES

Among other operations, central and side holes, as well as flared holes, are the most notable processes that Metalpress carry out.

Another option available is flanges, which can be either standard or customized. The perfect anchorage of the flanges to the convex bottom is ensured by accurate control processes during their production.

Øi Internal diameters Nominal thicknessH Flared height

Øimm

smm

Hmm

90 2,5 11

108 2,5 20

109 2,5 13

110 2,5 20

122 3 15

125 4 15

130 3 20

162 3 20

175 3 20

182 2 20

210 2 15

225 3 13

12

TYPE D TORISPHERICAL DIN28011 DISHED HEADS

TYPE “D”TORISPHERICAL HEAD

FONDI STAMPATI

TIPO “D”DIN28011

R = Øe Øe10r =

Øe External diameter

H Standard height including thickness

R Spherical radius

r Connector radius between spherical and cylindrical parts

s Nominal thickness

h1 Minimum height

P Weight in kilograms per mm of thickness

V Volume in litres

Øemm

Hmm

Rmm

rmm

smm

h1mm

Pkg

Vlitres

130 185 130 13 2÷2,5 26 0,134 1,3

160 56 160 16 2 32 0,3 0,9

200 60 200 20 1,5÷3 39 0,42 1,3

220 70 220 22 1,5÷3 42 0,52 1,9

240 60 240 24 1,5÷3 47 0,53 1,8

250 70 250 25 1,5÷3 48 0,62 2,5

270 70 270 27 1,5÷3 52 0,68 2,8

280 75 280 28 1,5÷3 54 0,75 3,2

300 80 300 30 1,5÷3 58 0,86 4,1

315 80 315 31,5 1,5÷3 61 0,92 4,4

318 80 318 31,8 1,5÷3 62 0,93 4,5

320 80 320 32 1,5÷3 62 0,94 4,5

350 85 350 35 1,5÷3 68 1,10 5,7

360 85 360 36 1,5÷3 70 1,14 5,9

380 95 380 38 1,5÷3 74 1,32 7,6

400 100 400 40 1,5÷3 78 1,47 8,9

420 100 420 42 1,5÷3 81 1,56 9,6

430 105 430 43 1,5÷3 83 1,67 10,7

450 105 450 45 2÷3 87 1,77 11,4

500 110 500 50 2÷3 97 2,11 14,4

550 120 550 55 2÷3 107 2,53 19,1

600 130 600 60 2÷3 116 3,00 24,5

630 160 630 63 1,5÷3 123 3,4 35,2

650 140 650 65 2÷4 126 3,51 31,1

700 150 700 70 2÷4 136 4,1 39

750 160 750 75 2÷4 145 4,65 47,1

790 180 790 79 3÷5 154 5,4 60

850 180 850 85 3÷5 166 6 68

860 180 860 86 1,5÷3 170 6,3 70

950 225 950 95 1,5÷4 183 7,9 110

1000 235 1000 100 3÷5 194 8,8 130

1100 250 1100 110 3÷5 214 10,4 165

1200 270 1200 120 3÷5 233 12,3 211

1250 280 1250 125 3÷5 243 13,3 239

Custom made diameters can be made.Feel free to ask for an offer.

TYPE E SEMI ELLIPSOIDAL DIN28013

R = Øe • 0,8

Øe6,5r =

Øe External diameter

H Standard height including thickness

R Spherical radius

r Connector radius between spherical and cylindrical parts

s Nominal thickness

h1 Minimum height

P Weight in kilograms per mm of thickness

V Volume in litres

Øemm

Hmm

Rmm

rmm

smm

h1mm

Pkg

Vlitres

200 75 160 31 1,5÷3 51 0,44 1,7

220 85 176 34 1,5÷3 55 0,57 2,2

240 85 192 37 1,5÷3 61 0,61 2,7

265 99 212 40 1,5÷2,5 68 0,81 4

273 80 218 42 1,5÷3 69 0,71 3

280 95 224 43 1,5÷3 71 0,80 4,2

300 105 240 46 1,5÷3 76 0,94 5,4

318 105 254 49 1,5÷3 81 1,02 5,9

320 110 256 49 1,5÷3 81 1,06 6,4

350 120 280 54 1,5÷3 89 1,26 8,3

360 120 288 55 1,5÷3 92 1,31 8,7

400 135 320 62 1,5÷3 102 1,63 12,2

420 140 336 65 1,5÷3 107 1,78 13,9

430 140 344 66 1,5÷3 109 1,84 14,5

450 150 360 69 2÷3 114 2,05 17,1

500 165 400 77 2÷3 127 2,51 23,2

550 175 440 85 2÷3 140 2,97 29,4

600 190 480 92 2÷3 153 3,52 37,9

650 200 520 100 2÷4 165 4,05 46,5

750 230 600 115 2÷4 191 5,39 71,2

790 230 632 121 3÷5 202 5,9 77

800 240 800 80 3÷4 154 6,1 83

1000 295 800 154 3÷5 255 9,5 161

1100 300 880 169 3÷5 281 10,9 189

1200 340 960 185 3÷5 306 13,3 264

1250 345 1000 192 3÷5 319 14,2 283

Custom made diameters can be made.Feel free to ask for an offer.

14

t

r

DISHEDHEADS

TYPE OF EDGE AVAILABLEDimension “ ” to request

TYPE OF EDGES AVAILABLE

t

r

DISHEDHEADS


t

r

DISHEDHEADS


t

r

DISHEDHEADS


R

T

U

B

Trimmed edge

Trimmed and turned edge

Trimmed and rolled edge

Inside beaded edge

Dimension “P” to request

t

r

DISHEDHEADS


B45

M

S

Z

45° bent edge

Inside chamfered beaded edge


Outside beaded edge


Outside chamfered beaded edge


t

r

DISHEDHEADS


t

r

DISHEDHEADS


t

r

DISHEDHEADS


16

900.1042.1Flange cover, 5 holes

900.0900.1Seal

900.0100.1Flange, 5 holes

Square head screw

Assembly scheme of flange, seal, flange cover and convex

bottom, 5 hole model

Assembly scheme of flange, seal, flange cover and convex

bottom, 8 hole model

900.1055.1Flange cover, 8 holes

900.0600.1Seal


Square head screw

FLANGED BOTTOMS


D. 180

900.1500.1External bottom

900.1000.1Internal bracket

900.1400.1External bracket

900.0700.1Hanger for the enamelling

900.1502.1Lower external bottom


D. 220

900.1501.1Top external bottom

Note

Flanges and covers can be made in: several types and

diameters stainless steel carbon steel galvanized steel

18

DIE CONSTRUCTION

The dies and equipment building and maintenance department has numerical control (CNC) machine tools, wire and plunge EDM machines and grinding machines.

The wide range of processes available enable the technical team to design and manufacture

each die with extreme precision, which are also obtained by using an advanced three-dimensional CAD / CAM system.

Metalpress collaborates with 4 external partners for the construction of the dies.

TYPE OF DIES

Shearing tools Progressive dies Transfer dies Deep drawing tools Triple effect tools

DIE CONSTRUCTION

CO DESIGN

RTSSMED

OF THE PRODUCT

RAPID TOOL SYSTEM | SINGLE MINUTE EXCHANGE OF DIE

20

CERTIFICATION

QUALITY

UNI EN ISO 9001 2015 - 2017

6 SIGMA METHOD - 2018

UNI EN ISO 15614 - 2018

UNI EN ISO 9606 - 2018

UNI EN ISO 14732 - 2018

PED production process conformity 2018

UNI EN ISO 3834 - 2019

IATF 16949:2016 (ex ISO TS 16949:2009) - 2020

ENVIRONMENT

UNI EN ISO 14001 – 2019

SAFETY

OHSAS 18001 – 2020

The best way to predict your future is to create it.Abraham Lincoln

Drawing, figures and descriptions contained in this catalogue are only indicativeand do not bind the Manufacturer in any way.

Via Monte Corno, 10 | San Giovanni Lupatoto (Verona, Italy)

Tel. +39 045 8778602 | e-mail: [email protected]

www.metalpress.it

D I E S | S H E E T M E T A L F O R M I N G |

D I S H E D H E A D S F O R T A N K S

RENEWAL = expertise + continuous improvement of the process + innovation

ED

. 10

/18

Documents

DIES | SHEET METAL FORMING | DISHED HEADS FOR TANKS