High Performance Closed Die Forging Components voestalpine Customer Day, Aberdeen May 23rd, 2017 Manfred Foettinger
Imagevideo Watch the video at YouTube page 2
Company key figures (FY 2015/2016) RAW STEEL PRODUCTION 336.000 to DISPATCHES 233.000 to TURNOVER 379 mill. EMPLOYEES 1.439 APPRENTICES 72 Page 3
Buderus Closed Die Forging Introducing Buderus Edelstahl Introducing Closed Die Forging Operation Manufacturing Process Markets & Products Design Process Simulation Tools forging is more than beating on hot iron Page 4
Closed Die Forging : Market Position weight 200 kg 500 lb 2 kg 5 lb Open Die Forges 500 50,000 Böhler Closed Die Forge (Aircraft) Buderus Closed Die Forge Other Die Forges Passenger Car Parts pieces per year & article (typ.) steel forgings product weights: 2 200 kg/5 500 lbs production per year: 500 50,000 pcs. typical batch sizes: 500 5,000 pcs. frequence: 1/month 1/10 years approx. 500 active products (6) press lines: capacity 200 tons/day total production 50,000 tons p.a. 250 employees & associates Page 5
Tradition more than 9,000 articles since 1969 some articles more than 20 years continously in production Page 6
Forging Process APQP Order Design simulation raw part *) billet size CAD data forging parameters Tool Production die & cutting tool Billet sawing weighing spectroscopy Forging heating upsetting 1st & 2nd operation trimming Heat Treatment Final Inspection shot blasting NDT (MFI, ) rework dimensional insp spectroscopy certification packing Machining Surface Treatment Delivery Appr oval Appr oval Customer Material Certificate Q report PPAP Probing Q report *) or provided by customer
Plant Layout Material Storage & Sawing Tool Shop Heat Treatment Dispatch Center Closed Die Forge Final Inspection Railway track Page 8
Material Storage and Billet Sawing railway access highly automated - minimal manual work steel bars 8 m/26 long, Shelves size range: 55 mm/2 220 mm/8½ square storage capacity 5,000 tons Automatic crane railway & truck access spectroscopic material control sawing capacity 200 tons/day infeed trays saws scales (3) band saws + (5) high performance circular saws automatic scaling Robot palletising (to forge) ERP (SAP) link process monitoring Robot palletizing
Material Storage and Billet Sawing automatic crane material storage Robot palletising circular saw infeed trays Page 10
Overview: Press Lines standard operation: upsetting, forging in two dies, trimming inductive heaters overlapping load range: (1) article can be forged on min. (2) presses cassette tool holder system (3) press lines fully automated with robots process monitoring system linked to SAP system quality inspection: dimensional (3D scanner) & Magnaflux 11
Overview: Press Lines Inductive Heating [tons/h] Upsetting Press [tons] Main Press [tons] Trimming Press [tons] Robots 2 205 2,500 315 1 3.2 500 3,500 500 1 3.2 630 4,500 500 1 3.2 800 6,300 1,000 7 2 x 4.2 1,600 8,000 1,200 9 2 x 3.2 1,200 10,000 1,000 8 Piece weights [kg] 2 10 5 22 lbs 4 20 9 44 lbs 6 30 13 66 lbs 8 45 18 100 lbs 10 80 22 175 lbs 20 220 44 485 lbs Cassette Tool Holder
Automated Press Line Upsetting Press Main Press Trimming Press Robot palletising Cooling Belt
Heat Treatment Facility automated process: automatic handling except palletising individual, automatic cycle for each product capacity: 100 tons/day (5) high temperature + (5) low temperature furnaces gas-fired ovens for low emissions ERP (SAP) link process monitoring/data logging Quench bath Automatic crane furnaces control room shelves Processes: annealing +FP normalising +N quenching/tempering +QT with polymer bath Other heat treatment options: Buderus continuous furnace external partners Samples to laboratory Transfer zone Preparation zone Page 14
Heat Treatment Facility Loading the high temperature furnace Loading the low temperature furnace Page 15
Final Inspection (4) shot blasting systems PPAP defined inspection sequence spectroscopic inspection (3) partly automated MPI systems penetration testing ultrasonic testing dimensional inspection MPI Units Inspection & Packing Shot Blasting Units Page 16
Tool Shop 10 tool sets/day refurbishment &production CNC milling CNC lathes welding optical 3D scanner > 2,000 dies on stock
3D Optical Die Inspection new die after 1000 Pcs. Page 18
Forging Simulation Leg for Drill bit page 19
Application of Forging Simulation - Material Parameters - Machine kinematics - Process Parameter - Temperature - Tool Design -.. form filling forging failures fibre flow local velocity tooling load press load Page 20
Truck Example: Knuckles production 160,000 pcs. p.a./36 articles weight: 20-75 kg/44 165 lbs material grade: alloyed carbon steel/customer spec. variation heat treatment: quenched & tempered delivery condition: raw or 100% machined option: E-coat surface treatment safety part electronically linked delivery plan (JIT delivery)
Truck (1) raw part = 3-4 finished parts Example : Crown Wheel & Pinion production 320,000 pcs. p.a./100 articles each crown wheels 20 96 kg/ 22 210 lbs; diameter: up to 500 mm/20 crown wheels: with or without hub pinions 15 45 kg/ 33 100 lbs; length: up to 420 mm/ 16½ material grades (typ.): alloyed carbon steel/customer spec. variation heat treatment: annealed delivery condition: raw part/shot blasted electronically linked delivery plan (JIT delivery)
Industrial Example: Hydraulic Accumulators 1000 bar/15,000 psi production 90,000 pcs. p.a./12 articles diameter 100 180 mm/ 4 7 weight 2 9 kg/ 5 20 lbs material grade: carbon steel, stainless steel (AISI 316) heat treatment: quenched & tempered delivery condition: raw/shot blasted high pressure component: certified by German TÜV
Industrial Example : Crank Shaft Counterweights production 60,000 pcs. p.a./10 articles weight 10 30 kg/ 22 66 lbs material: carbon steel/micro alloyed heat treatment: quenched & tempered delivery condition: 100% machined safety part
Industrial Example: Balls for Ring Bearings production 5,000 pcs. p.a./10 articles diameter 75 350 mm/3 14 weight 2,5 180 kg/ 5 400 lbs material grade: 100Cr6 & variations (AISI 52100) heat treatment: annealed delivery condition: raw/shot blasted project bound delivery: exact quantity
Tunnel Boring Machines Example: Cutting Rings production 15,000 pieces p.a./12 articles diameter 170 500 mm/6,5 19 nominal weight: 5 50 kg/ 11 110 lbs material grade: high alloyed Buderus special steel heat treatment: tempered delivery condition: machined & raw part
Rock Drilling Example: Drill Bit production 25,000 pieces p.a./4 articles length 300 400 mm weight: 15 38 kg material grade: 1.6790 heat treatment: tempered delivery condition: raw part
Rock Drilling Example: Legs (& Cones) for Rotary Drill Bit production 20,000 pieces p.a./8 articles length 170 500 mm weight: 14 60 kg material grade: 21NiCrMo22 heat treatment: tempered delivery condition: raw part
Process Technology Example: Valve Cone for Slurry Pump production 2,000 pieces p.a./2 articles, friction welded diameter 380 mm weight: 100 kg material grade: 1.7131 heat treatment: normalized delivery condition: raw part/pre machined
Oil Field Application Example: Plug Valve production 45,00 pieces p.a./3 articles diameter 100 200 mm weight: 10 30 kg material grade: stainless AISI410 heat treatment: annealed delivery condition: raw part
Gas Lift Operations Example: Side Pockets for Gas Lift Mandrels production 5,000 pieces p.a./2 articles length 600 mm/24 weight: 10 15 kg/ 22 33 lbs material grade: 34CrMo4 heat treatment: normalized delivery condition: machined
Buderus Competence ENGINEERING MATERIAL TECHNOLOGY QUALITY! Page 32
Top producer of high-grade special steels OUR COMPANY ALL FROM ONE SOURCE OUR PROMISE SERVICE & QUALITY Buderus Edelstahl GmbH is one of the top producers of high-grade special steels in the world. From melting through to the end product, the whole production process takes place within the company. This ensures that we can guarantee our customers: Implementation of individual requirements Compliance with high quality standards Speed Our company is also characterized by: A high level of service A transparent and firstclass materials management and quality assurance system Flexibility when processing orders Short through-put times Page 33
Our products IN WETZLAR Our six business units produce products of the highest quality. WORLDWIDE We are a global player in: Automotive and drive technology Plant and machine engineering Tooling and mould making Page 34
Our production process Page 35
Our plant Tool Steel Stock Machining Heat Treatment Cold Rolling Mill Hot Rolling Mill Closed Die Forging Administration Open Die Forging Steel Mill Seite 36
History 1731 1884 1965 2005 2015 Johann Wilhelm Buderus I founds the Friedrichshütte on 14 March. Buderus goes public and becomes one of the first public limited companies in Germany. Merger with Röchling schen Eisen and Stahlwerken. Böhler-Uddeholm AG purchases 100 percent of the shares in Buderus Edelstahl. 1,400 employees generate an annual turnover of over 379 million euros. Johann Wilhelm Buderus II takes over the commercial and technical management of the Friedrichshütte charcoal furnace plant (Gießen district). Founding of the joint venture Stahlwerke Buderus-Röchling Aktiengesellschaft, later Edelstahlwerke Buderus AG. Buderus Edelstahl becomes part of Robert Bosch GmbH. The Austrian company voestalpine AG purchases Böhler-Uddeholm AG. 1836 1920 2003 2007 Page 37