Metal forming XXL – size: Complete solutions for all stages of metal forming have worldwide appeal
At the Hanover Fair 2014, at the collective booth of the German Forging Association, Siempelkamp introduces closed-die forging presses for forged parts made of aluminum and titanium alloys for the aircraft industry. Furthermore, the company presents the first ring-rolling mill manufactured in its 125 years of company history.
With these large plants, Siempelkamp proves its competence as a systems supplier and provider of complete solutions. Worldwide Siempelkamp is the only manufacturer that can offer exceptionally large plants from one source for all stages in the metal forming process – from the design, to the casting, to the machining of the cast components, to the installation, to the startup at the customer“s site.
Nanshan: Closed-die forging press made in Krefeld is the heart of a new plant
A current example for complete solutions is the 500 MN (55,115 US t) closed-die forging press which will be the heart of a new forging mill of the Chinese Nanshan Group. The press will manufacture forged parts made of aluminum and titanium alloys for the Chinese aircraft industry. Siempelkamp has been commissioned with the design, construction and installation of the complete plant.
The heavy parts of the press are made of spheroidal graphite iron and weigh up to 300 t (330 US tons). These components were cast at Siempelkamp Foundry and then machined at the Siempelkamp Machine Factory. Both companies are located on the same premises. Furthermore, as part of this large project, the customer ordered another 125 MN (13,778 US t) closed-die forging press for different applications in the beginning of 2013. Both presses are currently built in Krefeld.
The technical data of the 55,115 US t press clearly illustrate the challenges: Due to the large dimension of the 4 x 7 m (13 x 23 ft) press table, the clearance between the columns amounts to 5 x 3 m (16 x 10 ft). Eight cylinders are responsible for the movement of the moving beam. With an output of roughly 24 MW the energy-efficient oil-hydraulic drive, developed by Siempelkamp, applies a pressure of 420 bar.
The innovative strain rate control compensates high eccentric loads. It also allows extremely low forging speeds for the forming of very challenging geometries and materials used in the aerospace industry.
Ring-rolling: First time for Siempelkamp
For the first time in the company’s history, Siempelkamp has designed and built a ring-rolling mill. At its initial startup, it passed its crucial test at the Krefeld plant. Currently, the mill is being delivered to the customer JSC Metallurgical Plant Electrostal in Russia.
The ring-rolling mill will manufacture rings with an external diameter of up to 4,000 mm and a height of up to 600 mm made of steel and special materials such as nickel-based, titanium and aluminum alloys. It can apply maximum radial and axial pressing forces of 6,300 kN each.
The rings with rectangular or profiled cross-sections made of these extremely rigid yet lightweight special materials are mainly used as mechanically and thermally stressed components in the aerospace industry.
Siempelkamp not only completely manufactured the rolling mill at the Krefeld location but also assembled and started it up there as well as extensively tested the hot rolling process. The startup in Krefeld has proven that the plant not only meets the customer’s desired specifications but even exceeds them in some areas.
With a variety of design details, Siempelkamp achieves exceptionally high precision during ring rolling. For example, the diameter of the rings during ring rolling is precisely measured via laser measurement systems. High process accuracy is also guaranteed by the SicoRoll control which Siempelkamp specially developed for ring rolling.
Just as for both closed-die forging presses for the Nanshan Group, Siempelkamp supplied, next to the rolling mill, the complete hydraulic system, the automation technology as well as the SicoRoll control – the kernel of which simulates the dimensions of the blanks for the closed-die forging press.
Extensive FEM calculations are the guarantee for the high fatigue strength of the mechanical structural components. This is further supported by the fact that the housings for the tapered rolls, which experience high mechanical stresses, are designed as one-piece castings without weld seams.
Apart from investment security, the Siempelkamp design engineers focused on low total costs: especially for highly stressed component parts, such as the gears, many standard components were used. For our customer this translates into cost savings because maintenance becomes simple and spare parts are easily procured.
Siempelkamp at the Hanover Fair 2014:
Hall 4, Booth E42
Collective booth of the German Forging Association
Bildquelle:kein externes Copyright
About Siempelkamp
The Siempelkamp Group is a technology supplier operating internationally. The Group consists of three business units, the machinery and plants, the foundry, and the nuclear technology business units. As a systems supplier of press lines and complete plants for the wood-based products industry, as the world“s largest hand-molding foundry producing castings with a weight of up to 300 t (330 US tons), and as component supplier and service provider for nuclear facilities the company is internationally recognized.
Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG
Ralf Griesche, Marketing + Communications
Siempelkampstr. 75
D-47803 Krefeld / Germany
+49.2151.92-4636
ralf.griesche@siempelkamp.com
http://www.siempelkamp.com
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstr. 83
52072 Aachen / Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de
