Subcontracting. Cold forming machines Slotting machines

Transcription

1 Subcontracting ERNST GROB AG Cold forming machines Slotting machines

2 ERNST GROB AG Cold forming machines Slotting machines Rohrgasse 9, P.O. Box 830 CH-8708 Männedorf Switzerland Phone Fax Products and Services Cold forming machines ERNST GROB AG develops, designs and builds cold forming machines; from basic, manually loaded units to fully automated production lines. The primary fields of application for the sheet metal and solid components produced by cold forming are to be found in the automotive industry. Our machines, however, are also operational wherever efficiency and quality are key considerations. Slotting machines Sheet metal parts that have been splined on GROB cold forming machines can be transferred to our slotting machines for secondary operations, thereby ideally complementing the cold forming process. Non-splined workpieces can also be slotted. The design concept of our equipment is modular and can be optimally tailored to suit the specific requirements of the application involved. Tools All tools used on GROB machines are developed and manufactured in GROB s in-house tool shop in accordance with the specific requirements of the materials and applications involved. An in-depth expertise, plus state-of-the-art toolmaking equipment combined with continuous research and development allows ERNST GROB AG to provide optimal tooling delivered in the shortest possible delivery times. Subcontracting At our subcontract facility we use our own cold forming and slotting machines to produce components to customer order. We can take on your production needs for individual components or small pilot runs. To overcome production bottlenecks, we also process full-scale mass volumes. Our Quality Management System is certified to ISO/TS Engineering A cornerstone of our success is the relentless search for optimal solutions to specific engineering challenges. Our development department is key in this objective, as this is where years of in-depth experience and the latest technological expertise are merged. Close collaboration with our business partners invariably succeeds in generating innovative results that our test department rapidly converts into prototype components, which are already close to mass-production maturity.

3 Contents Page Company profile... 2 Intelligent complement... 4 Examples... 6

4 Subcontracting Company profile Competencies ERNST GROB AG develops, designs and builds precision machines dedicated to the cold forming of splined and nonsplined workpieces. The manufacture of slotting machines for secondary and finishing operations on cold formed workpieces is yet another core competence of the company. From the initial idea through to its development, and right up to the industrial application the entire concept is available from a single partner: ERNST GROB AG provides customer specific solutions, from manually loaded single machines to fully automated production lines. GROB slotting machines GROB slotting machines are employed to finish cold formed splined or non-splined hollow components. Diverse slotting and coining operations are undertaken at various stations. Separate stations for dedicated applications can also be integrated. Slotted workpieces Diversity of finished products Applications for GROB-Machines are highly flexible, for example, when producing: Clutch disc carriers Splined shafts Gearbox shafts Drive shafts Steering system parts Pump shafts Extruder shafts Splined shafts for: Printers Medical instruments Communal vehicles Helicopters Food processing equipment Torsion bars and progressive coil springs GROB cold forming technology Machines for the automotive industry GROB machines are primarily used in the automotive industry. Typical components are clutch disc carriers in automatic transmissions and other splined components within the power train. Gearbox shafts GROB cold forming machines GROB cold forming machines are based on the principle of the cold roll forming in planetary type movement process. The technology provides a solution for the cost-effective production of splined or reduction type cylindrical workpieces. The founder of our company, Ernst Grob, further developed and refined the principle (see infobox «The GROB story»). Components for a wide range of vehicles Thin-walled tubular components, cold rolled without support mandrels 2 Ernst Grob AG Subcontracting

5 Dedicated partnerships At ERNST GROB AG the development department is intensely focused on the refinement of existing technologies, plus the development of new processes and applications. In close cooperation with customers and other interested parties, solutions are generated that permit economic production of accurate finished parts. When required, ERNST GROB AG offers customer support throughout the entire service life of machines installed by our company. Locations ERNST GROB AG plants are located in Switzerland s greater Zurich conurbation where the company is able to benefit from an outstanding infrastructure with excellent transport facilities. Headquarters (administration, research, development, assembly) are located in Maennedorf, while the subsidiary (production, subcontracting) is to be found in Oetwil am See. Success factor employees The key success factor of ERNST GROB AG is the professional competence and dedication of its employees. A team of highly qualified and experienced specialists is the best guarantee for meeting the most demanding challenges. An innovative spirit coupled with an inherent flair for technical solutions are the foundation on which innumerable and unique developments are based. Quality inspection using state-of-the-art methodology Headquarters in Maennedorf The GROB story Subsidiary in Oetwil am See up to 1961 Dr. h.c. Ernst Grob develops cold forming machines at the machine tool works he founded in Munich in Dr. h.c. Ernst Grob founds a company making cold rolling machines in Maennedorf and delivers the first one to Sulzer, Zuchwil, Switzerland Further machine deliveries to Germany, Italy and Japan. Subsequent set-up of global sales and marketing network Introduction of PLC technology and establishment of in-house electrical department Introduction of multiple axis CNC technology Following death of Dr. h.c. Ernst Grob: establishment of ERNST GROB AG. Business continued and expanded by his grandson and current owner, Mr. Daniel Dériaz Acquisition and expansion of a subsidiary plant of ERNST GROB AG in Oetwil am See, Switzerland Quality Management Certification to ISO Expansion of product portfolio with type S8 slotting machine for hollow parts and delivery of first slotting machine to General Motors Strasbourg Start-up of production at the newly constructed workshop in Oetwil am See Certification of subcontracting facility in Oetwil am See to ISO/TS Introduction of torque drive technology (NCT) Modern centralised office building in Maennedorf is occupied Market roll-out of newly developed stroke-stamping process Opening of our own Beijing representative office. 50 years jubilee of ERNST GROB AG. ERNST GROB AG Rohrgasse 9 CH-8708 Männedorf Phone Fax info@ernst-grob.com 3

6 Subcontracting Intelligent complement Possibilities For customers needing limited volumes of components, investing in a complete production line does not always make economic sense. ERNST GROB AG has its full range of machines installed in-house and is therefore well able to process small series on subcontractor base. We also offer this service to overcome production bottlenecks or loss of output, e.g. arising from maintenance periods. Deadline problems relating to production start-ups can also be solved by relying to our subcontractor facility. As a wide range of machine models are available at ERNST GROB AG, all production processes are catered for. Clamping solutions for individual components and small series can be generated at reasonable cost, while machines equipped with robots can be used for large volume output. Subcontractor facility Situation analysis Depending on the workpiece specifications, our specialists will define the optimal process and approach. Their focus is invariably on the biggest potential customer benefit. Thanks to a substantial level of in-house manufacturing depth, customer-specific modifications to machines or elements matching the workpiece can be achieved at short notice. Production line with forming and slotting machine 4 Ernst Grob AG Subcontracting

7 Production start-up We offer our customers the possibility of producing their pilot runs or ramp-up series at our in-house facility. This allows the period up to commissioning of the customer s own equipment to be bridged productively. As operation is undertaken with the same tooling, using an identical process, the workpieces are as close to final production status as possible. Project review Series production We are also the partner of choice for small series and even for individual components: we have the ideal combination of know-how and expertise. Equipment for virtually all processes is available in-house. State-of-the-art design and manufacturing of workpiece-specific clamping devices are assured. High-volume components can be produced in multi-shift operation. We take production compatibilty into account at the design stage already. Our Quality Management System has been certified to ISO/TS since Small series production of spline shafts Serial production of clutch disc carriers ERNST GROB AG Rohrgasse 9 CH-8708 Männedorf Phone Fax info@ernst-grob.com 5

8 Subcontracting Examples Formable materials Practically all commercially available steels for case-hardening and heattreatment with a tensile strength of up to 1500 N/mm² can be considered as suitable. GROB cold forming technology can also process stainless steels such as those used in pump construction. Depending on their alloy content, alternatives to steel, such as nodular cast iron, aluminium, titanium and non-ferrous metals can also be cold formed. ERNST GROB AG has extensive experience in the processing of a wide range of materials. Splined bronze and aluminium tubes Chrome steel clutch disc carrier Workpiece examples Cold forming of solid material Typical applications are powertrain components such as gearbox shafts. Either standard splines or customized types such as parallel flanked, ball bearing or buttress profiles are possible. Forming of bar material Wheel hub with SAE spline 6 Ernst Grob AG Subcontracting

9 Bar material Very long splines, for example on extruder worm gear shafts, can be formed up to lengths of 10 m or more. Dissimilar, aligned splines for the coupling and worm ends are possible. Forked shaft for steering system Splined thin-walled tubular component Cold formed bar material DIN 5480 Spline with formed assembly chamfer Shafts with parallel flanked splines Transmission shafts with multiple, aligned splines Stainless steel pump drive shafts ERNST GROB AG Rohrgasse 9 CH-8708 Männedorf Phone Fax info@ernst-grob.com 7

10 Subcontracting Forming sheet metal parts One of the primary benefits of clutch disc carriers formed from sheet metal is weight saving. Numerous variants of splining on inner and outer clutch disc carriers are possible: Internal and external splines Only internal or external splines From blanks or from cup-shaped sheet metal preforms. Slotting sheet metal parts Cold formed sheet metal parts frequently require secondary operations. Typical ones are: Trimming to length Stamping lubrication slots Coining in snap ring grooves Producing centerholes These operations are carried out on slotting machines developed in-house. Non-splined rotationally symmetric components can, of course, also be slotted. The majority of such operations can be carried out from inside to outside or vice versa. Reduction By reduction, for example of torsion bars for chairlifts, the diameter of the stock material is reduced without the need for machining. Thanks to the chipless forming process, the orientation of the grain flow remains unbroken, the microstructure is homogenous, there is the benefit of work hardening and substantial savings in weight and material are achieved. Tapered reduction on helical spring billet Clutch disc carrier with internal and external splines Non-splined slotted component Material savings on reduced torsion bar Clutch disc carrier formed from a flat disc blank Clutch disc carrier after 5 slotting operations Splined fork shaft in reduced fork shaft sleeve with internal spline 8 Ernst Grob AG Subcontracting

11 ERNST GROB AG Cold forming machines Slotting machines Rohrgasse 9, P.O. Box 830 CH-8708 Männedorf Switzerland Phone Fax Airport Zürich-Kloten Bern/Basel A1 Schaffhausen A51 Schaffhausen A4 Kreuzlingen A7 St. Gallen A1 Winterthur A1 Zürich A53 Uster ERNST GROB AG A3 Horgen Meilen Oetwil Männedorf Rapperswil A3 Chur EGAG Lohnfertigung de-en v1.3 ks