Metal forming presses: New installations and upgrading of large presses in Russia and China
At the shared booth of the German Forging Association at the Hannover Fair Siempelkamp introduces single-source solutions for new installations and upgrading of exceptionally large plants for all stages of metal forming.
With two current large projects the company proves its high competence as a systems supplier and provider of complete solutions: At Electrostal in Russia with presses along the entire process chain for the manufacture of rings with a diameter of up to 4,000 mm and at Dalian Shijie in China with a 200 MN closed-die forging press. Siempelkamp is the world“s only manufacturer for large metal forming presses which can provide the entire range of services from a single source including the casting and machining of the parts all the way to their installation and startup at the customer’s site.
Electrostal: From forging the pre-forms to manufacturing the ring blanks to the finished ring
With the new ring-rolling mill Siempelkamp has expanded its product portfolio by additional production stages. With a complete concept the Russian customer Electrostal is able to carry out the entire ring manufacturing process from melting the metal to the production of the pre-forms to the finished rolled ring. The customer, a supplier to the aerospace industry, integrated two Siempelkamp plants into its production facility. Furthermore, Siempelkamp is currently retrofitting an existing press into a multi-function press.
The new 200 MN closed-die forging press is the first one of this dimension with an integrated tool heating system. This tool heating system keeps the upper and lower die at a constant 800 °C between forging processes. With the press Electrostal will manufacture, among other products, creep-resistant forgings with lengths of up to 1,200 mm and widths of 800 mm.
Prior to delivering the closed-die forging press, Electrostal ordered from Siempelkamp a ring-rolling mill for the subsequent production process. With maximum radial and axial pressing forces of 6,300 kN each, the ring rolling mill is one of the largest of its kind. The Electrostal press was successfully started up in June 2014. The mill was initially designed to produce rings made of steel and special materials such as nickel-based, titanium, and aluminum alloys with a maximum diameter of 2,500 mm. During the testing phase in Krefeld, the maximum diameter was extended to 4,000 mm; the maximum ring height is about 600 mm. Next to the rolling mill, the scope of supply for Electrostal also includes the complete hydraulic system, the automation system as well as the newly developed SicoRoll control.
The latest component of this project is for Siempelkamp to retrofit the customer’s existing 4,000 t open-die forging press. In addition to open-die forging, the press will also be able to carry out closed-die forging processes after the upgrade and can thus be regarded as a multi-function press. As part of the retrofit, Siempelkamp will overhaul the water hydraulic control of the press. With the new control Electrostal achieves a +/- 1 mm tolerance with the movable beam during the pressing process.
Dalian Shijie Aviation Forging: Simultaneous engineering with the in-house foundry
Siempelkamp is currently designing a 200 MN closed-die forging press for Dalian Shijie Aviation Forging Co. Ltd., based in Dalian in the Chinese province of Liaoning. The customer will manufacture components made of titanium and nickel-based alloys, for example, for jet engines as well as parts made of aluminum for the aircraft industry. The customer also intends to use the new press to produce components for rail vehicles and for the oil and gas industry.
The closed-die forging press will apply a pressure of 200 MN; the dimensions of the press table will be 4,000 x 2,200 mm. The press will allow the forming of very large parts as well as the forming in stages with several forging dies. The press will have a stroke of 2,000 mm. The oil-hydraulic drive will generate a pressure of up to 420 bar.
The press is equipped with four main cylinders as well as four lifting (balancing) cylinders for the top bolster. The bottom bolster alone weighs 265 t. Samiron Mondal, Managing Director at Siempelkamp, sees the competitiveness of Siempelkamp on the international stage proven: „Obviously, the customer has awarded the contract to us because we can supply the complete press from one source. Worldwide we are the only manufacturer that can design, cast and machine the extraordinary large components for metal forming presses made of spheroidal graphite iron in our own factory in Krefeld. The fact that this is not the first time we have built presses with large dimensions provided our customer with a sense of reliability during project handling. High quality ‚made in Germany‘ and proven adherence to schedules meant more to our customer than the geographic proximity to other manufacturers.“
Siempelkamp at Hannover Fair 2015:
April 13 to 17, 2015
Hall 4, Booth E42
Shared booth of the German Forging Association
About Siempelkamp
The Siempelkamp Group is a technology supplier operating internationally and consisting of three business units: the machine and plant engineering, the foundry technology, and the nuclear technology business unit.
Siempelkamp machine and plant engineering is a systems supplier of press lines and complete plants for the wood-based panel industry, the metal forming industry as well as the composite and rubber industry. The Siempelkamp foundry is the world“s largest hand-molding foundry producing castings with a weight of up to 320 t (353 US tons). Siempelkamp nuclear technology is a component supplier and service provider for nuclear facilities.
Firmenkontakt
Siempelkamp Maschinen- und Anlagenbau GmbH
Ralf Griesche
Siempelkampstraße 75
47803 Krefeld / Germany
+49.2151.92-4636
+49.2151.92-5683
ralf.griesche@siempelkamp.com
http://www.siempelkamp.com
Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstr. 83
52072 Aachen / Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de
