Viking Forge Corp. If you want to be sure FORGE IT!!!

Transcription

1 Viking Forge Corp. If you want to be sure FORGE IT!!!

2 Viking Forge An ISO 9001:2000 Company

3 Offices: 4,000 Square Feet Tool & Die Shop: 12,000 Square Feet Forging Operations: 78,000 Square Feet 20 Acres Of Land For Future Expansion

4 Tool Making Equipment 1 Daewoo Puma 200 CNC Turning Center 1 Daewoo Puma 400 CNC Turning Center 2 Hermle C800V CNC Vertical Machining Center 1 Hermle C1200U 5 Axis CNC Vertical Machining Center 1 Alpha 1550S Lathe 2 VKM3 Milltronics Partner Mills 1 Fully Automated Die Welding Cell Miscellaneous support equipment

5 Steel Cutting Equipment Metric Ton Ficep Fully Automated Hydraulic Shear 1 4 Diameter Amada CM-100 Automated Cold Saw 1 4 Diameter Nishijimax NHC-100 Automated Cold Saw 1 6 Diameter Nishijimax NHC-150 Automated Cold Saw 2 12 X 16 Amada HA400 Automatic Saws 1 10 X 12 Amada HA250 Automatic Saw

6 Heating & Forging Equipment kw Inter-Power Induction Heating Billet Furnaces kw Inter-Power Induction Heating Billet Furnace kw AEG Elotherm Induction Heating Billet Furnace Ton National Forging Press Ton Bliss Forging Press Ton National Forging Press Ton National Forging Press Ton Erie Forging Press Ton Erie Forging Press

7 Finishing & Inspection Equipment 2 24 Cubic Foot Goff Tumble Blast Machine 1 3 Cubic Foot Wheelabrator Tumble Blast Machine Ton Chester Hydraulic Cold Coining Press Ton Waterbury Hydraulic Cold Coining Press 1 New Age 9000 Automatic Brinell Tester 1 New Age ME-2 Automatic Rockwell Tester 1 MagnaFlux Magnetic Particle Inspection Machine 1 Brown & Sharpe Excel CMM 1 Mitutoyo B715 CMM 1 Mitutoyo PH350 Optical Comparator

8 Engineering Software SolidWorks 3-D Solid Modeling CAD System SmarTeam Product Data Management System SmartFlow Workflow Management System Q-Form 3-D Finite Element Analysis GibbsCAM CNC Programming System

9 Quality Assurance Software PC-DMIS CMM Programming System DataPage CMM Statistical Data Collection System Kurt Check SPC Data Collection System GAGEtrak Calibration Management System Minitab Statistical Analysis System

10 Forging Defined Forging is the plastic deformation of metal into desired shapes using custom tooling and specialized equipment. It can be performed at various temperatures as defined below: - Cold Forging - 0 to 500 o Celsius - Warm Forging to 800 o Celsius - Hot Forging to 1100 o Celsius

11 Basic Impression Die Forging Hammer or Press In the most basic example of impression die forging, which accounts for the majority of forging production, two dies are brought together and the workpiece undergoes plastic deformation until its enlarged sides touch the die side walls Then, some material begins to flow outside the die impression, forming flash. The flash cools rapidly and presents increased resistance to deformation, effectively becoming a part of the tool. This builds pressure inside the bulk of the workpiece, aiding material flow into unfilled impressions.

12 Typical Mechanical Press

13 Typical Forging Progression

14 Precision Forging Forging close to finished size to minimize machining Tolerances tighter than typical Refinement and improvement of existing forging practice Limited to extremely high quality applications due to economics Complex geometries

15 Conventional vs. Precision Forging Before After

16 Complex Shapes

17 Flashless Forging Flashless forging is a type of precision forging Die cavity is completely closed during forging process Volume control is critical Requires stringent process controls Additional forging costs are offset by reduced machining costs

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19 Forging Video

20 Forging Tooling Case Studies

21 Tool Steel Case Study # 1 Turbine Hub LUK / Allison Transmission / GM

22 Turbine Hub Solid Model EPRT

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24 Solid Model of Bottom Finish Die

25 New Bottom Finish Die

26 Forge & Trim Die Assembly Solid Models b1092fa.easm Forge b1092ta.easm Trim

27 Finite Element Analysis/ Material Flow Simulation

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30 Comparative Results: Bottom Finish Die Failure Die Material Mode Life Standard H-13 Wear 17,420 Dievar Wear 39,626 Overall Improvement: 220% LUK / Allison Transmission / GM

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33 Comparative Results: Trepan Tool Failure Die Material Mode Life Std./ESR H-13 Wear 4,250 Dievar Wear 7,370 Overall Improvement: 73% LUK / Allison Transmission / GM

34 Tool Steel Case Study # 2 Drive Flange Magna Steyr / ZF / Mercedes

35 Drive Flange Solid Model EPRT

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38 Solid Model of Bottom Finish Die

39 New Bottom Finish Die

40 New Bottom Finish Die Insert With Shrink Ring Assembled

41 Forge & Trim Die Assembly Solid Models a1161fa.easm Forge a1161ta.easm Trim

42 Finite Element Analysis/ Material Flow Simulation

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45 Comparative Results: Bottom Finish Die Failure Die Material Mode Life Standard H-13 Breakage 2,650 Dievar 67% wear 5,990 33% breakage Overall Improvement: 126% Magna Steyr / ZF / Mercedes

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47 Comparative Results: Top Finish Die Failure Die Material Mode Life Std./ESR H-13 Wear 2,146 Hotvar Wear 6,251 Overall Improvement: 191% Magna Steyr / ZF / Mercedes

48 Tool Steel Case Study # 3 Wheel Hub Tochigi Fugi / GKN / Bombardier

49 Wheel Hub Solid Model EPRT

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52 Solid Model of Bottom Finish Die

53 New Bottom Finish Die

54 New Bottom Finish Die

55 Forge & Trim Die Assembly Solid Models b1174fa.easm Forge b1174ta.easm Trim

56 Finite Element Analysis/ Material Flow Simulation

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58 Comparative Results: Bottom Finish Die Failure Die Material Mode Life Standard H-13 Wear 2,600 Dievar Wear 5,360 Overall Improvement: 110% Tochigi Fugi / GKN / Bombardier

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61 Comparative Results: Top Die Posts Failure Die Material Mode Life Standard H-13 Wear 1,450 Hotvar Wear 3,110 Overall Improvement: 115% Tochigi Fugi / GKN / Bombardier

62 In Summary

63 Design Factors that Affect Tooling Cost Thin sections Number of holes and their proximity Radii and fillets Surface finish and cosmetics Special markings/identification Stock allowance Tolerances

64 Tooling Cost Components Relative Importance Design Tool steel Heat treat Nitride Machining Percent of Total Cost Machining Design Tool steel Nitride Heat treat

65 Tool Steel Supplier Evolution Past Practice H-13 is H-13 Many Suppliers Lowest Price Wins Current Practice H-13 is not H-13 Match Grade with Application 2 Suppliers Highest Quality at a Competitive Price

66 Historical Purchases Uddeholm $ $10, $470, $510,000

67 Tool Steel Heat Treat & Nitride Past Practice Heat Treat is Heat Treat, Nitride is Nitride Multiple Heat Treaters and Nitriders Multiple Heat Treat and Nitride Processes Hardness Call-out HRc Lowest Price Wins Current Practice Single Heat Treat and Nitride Source Match Process with Application Hardness Based on Die Size and Configuration Must be Competitive with Like Processes

68 Future Expectations for Tool Steel Greater Strength Better Wear Resistance Not Necessarily Lower Cost

69 Questions and Answers THANK YOU UDDEHOLM TOOLING THINK FORGING!!!