Forging
Forging
SCHULER FORGING. As a leading supplier of cold, warm and hot forging systems, Schuler offers everything from a single source from component development and process planning through die making and turnkey installation of efficient production systems. This deep experience of forging technology offers a decisive competitive advantage for productivity and quality. This overview of extensive products and services provides comprehensive solutions for producing forged products with high part quality, maximum production availability and reliable process engineering. The Schuler team is ready to put it into motion. Schuler welcomes a challenge.
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FORGING PROCEssEs SYSTEMS FOR COLD FORGING SYSTEMS FOR WARM FORGING SYSTEMS FOR HOT FORGING ADDREssEs aND SChULER SERVICE
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FORGING PROCEssEs
At a GLaNCE
FORGING pROCEssEs
Schuler offers the entire process development from a single source, including consulting and training services.
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To determine the best economic solution to produce quality parts, development of the forging process begins with part design, and must simultaneously consider material selection, process technology, production stages and die processes.
The part design and process plan form the basis for calculating the economic efficiency in the project planning phase. This means that the decision to use a forging process has been decided. Furthermore, the process plan provides information about the forging equipment required, the die system and the transfer system. These parameters must be considered simultaneously in order to achieve an optimum result.
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FORGING PROCEssEs
PROCEssEs
Reduction
Ironing
Backward extrusion
Lateral extrusion
REDUCTION. Reduction is a forging process in which the workpiece is forced through an opening in the die, fully or in part, involving a reduction in its cross section. Tapering of solid bodies results in a reduction in cross section, whereas hollow bodies, by contrast, are necked.
EXTRUSION. Extrusion is a single or multi-station production process for creating both hollow and solid bodies. The process is distinguished according to the direction of material flow: forward, backwards or lateral. The workpiece is forced through an opening in the die with reduced cross section giving the workpiece its shape.
IRONING. Ironing is carried out by pulling the workpiece through an ironing ring with the help of a punch. The wall thickness of the hollow body is reduced in this process.
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FORGING PROCEssEs
Upsetting
Piercing
Trimming
CLOsEd dIE fORGING. Closed die forging is a forging process in which dies move towards each other and cover the workpiece in whole or in part. The heated raw material, which is approximately the shape or size of the final forged part, is placed in the bottom die. The shape of the forging is incorporated in the top or bottom die as a negative image. Coming from above, the impact of the top die on the raw material forms it into the required forged form.
UPSETTING/OPEN DIE FORGING. Upsetting and open die forging are also forging procedures. Upsetting is principally used for preliminary distribution of the material. In contrast to closed die forging, the workpiece is not completely enclosed during this forging process.
PIERCING/TRIMMING. Piercing is used for incorporating holes and openings into a workpiece, which can have a wide range of shapes and sizes. Trimming involves removing surplus material (flash) from the workpiece.
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FORGING PROCEssEs
TEMpERAtURE RANGEs
Closed die forging Forging ring blanks Upsetting Open die forging Extrusion Piercing/trimming
COmpREHENsIVE RANGE Of pROdUCts ANd sERVICEs Schuler system solutions. As a leading supplier of cold, warm and hot forging systems, Schuler offers you a decisive advantage over your competitors for productivity and quality. Temperature ranges. The different temperature ranges in forging are an important factor when selecting the process and for successful commercial production.
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FORGING PROCEssEs
FORGING PROCEssEs
PROCEss DEVELOpMENt
The object of developing the part design and process plan is to ensure that economical production can be achieved. It is necessary to consider the specific application and production situation. For example, if the production volumes are low, then the objective is to achieve a process with only a few forging stations, and to plan for more complex secondary machining. An effective part design and process plan relies on know-how and practical experience. During development of the process plan, the decision is made which forging process or which combinations of forging processes should be used: e.g. full forward extrusion, backward extrusion, reduction, upsetting, etc.
WaRm FORGING
COLD FORGING
Sequence development
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FORGING PROCEssEs
DIE CONSTRUCTION
1 Ejector pin 2 Thrust piece 3 Pneumatic spring 4 Inner punch 5 Outer punch 6 Spraying ring 7 Die 8 Reinforcement 9 Counterpunch 10 Thrust piece 11 Ejector pin
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DIE CONSTRUCTION . In practice, a critical part of die development is the configuration of the punches and dies. Not only the punches and dies are accommodated in the die holder, but also the other die elements. Modern forging dies are configured for various stations. This means additional forging, calibration, punching or trimming procedures are possible in the same operation (using four- or five-station die sets commonly found in operation today). Special dies, such as closing dies, can also be used. This significantly reduces production costs related to additional processing after the forging process.
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FORGING PROCEssEs
FORGING PROCEssEs
COOLING DEVICE
Die cooling and lubrication systems for warm and hot forging.
DIE COOLING AND LUBRICATION. In warm and hot forging presses, effective cooling and lubrication systems are required. The shown solutions can provide optimum lubrication placement. In addition, the duration of the cooling and lubrication process can be optimized. This is an advantage compared to other systems such as linear manipulators, swivelling systems or systems that are mounted on transfer rails.
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FORGING PROCEssEs
PARt fEEd ANd tRANspORt sEQUENCE ANALYsIs. In the analysis of part handling, the path of every motion axis (slide, ejector and transfer) is coordinated. The data acquired in the handling analysis, such as travel distance and movement start/ end points can then be transferred directly into the machine control.
THE OBJECTIVES OF THE PART FEED AND TRANSPORT SEQUENCE ANALYSIS Implementing a design with the maximum transport safety and max. output Collision-free transport of parts from station to station Quick and safe die commissioning Increased stroke rate/output
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FORGING PROCEssEs
FORGING PROCEssEs
Process development
Die design
Schuler offers you individual solutions for all requirements in forging irrespective of whether you need an individual press for manual operation or you are looking for a large turnkey solution. Schuler is also your expert partner for modernizations, conversions or performance increases. Increasing product qualities, small batch sizes and just-in-time deliveries: Manufacturing forged components places demanding requirements on production systems and automation. Rely on Schuler's extensive expertise as a leading system supplier for cold, warm and hot forging. Whether small or large components, precision forgings or other technical challenges are involved, Schuler supports you in component development involving process development and diemaking through to the startup of your machine.
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COLD FORGING
At a GLaNCE
Cold forging allows components to be manufactured with very high dimensional accuracy combined with impressive output rates. By the very nature of the process, there is no scale formation or shrinkage, and the die wear is also very low. The material is not heated prior to forging in this process. The strain-hardening resulting during forging makes it possible to achieve elevated component strength levels while using low-cost raw materials. Cold forging machines are suited to a wide range of components. This range includes components for engines, gearboxes and suspension systems that have small length/diameter ratios as well as long-shaft components such drive shafts, gearbox shafts and axles with large length/diameter ratios. Our customers from all over the world manufacture CO2 cartridges, shock absorbers and hollow shafts on ironing presses.
HyDRaULIC COLD EXtRUsION PREssEs HyDRaULIC IRONING PREssEs KNUCkLE-JOINt PREssEs KNUCkLE-JOINt PREssEs WIth SERVODIRECt TEChNOLOGy FORmMastER FORmMastER WIth SERVODIRECt TEChNOLOGy
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COLD FORGING
HIGH FLEXIBILITY ENSURES MAXIMUM ECONOMY. The great flexibility of hydraulic systems is due to the ability of the user to program strokes, forces and speeds to fit the specific application, which makes cold forging an attractive solution. Single and multi-station hydraulic presses have an unlimited working capacity, offering tages especially for long shaft-shaped parts. advan Multi-station hydraulic presses require a very rigid press frame in conjunction with a tall slide in order to absorb the high off-center loads which result from the different force requirements of the individual stations. Schulers patented RingValve prefill valves significantly shorten the cycle time of the hydraulic press. These valves provide fast filling of the hydraulic cylinders during rapid closing.
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The pressure in the cylinder can be released quickly so that the slide will start the return stroke without delay. Unlike traditional prefill valves, RingValve prefill valves can be opened under maximum pressure at bottom dead center, which significantly shortens the press release portion of the cycle. Presses with three cylinders allow Dynamic Force Control (DFC) to be used. The oil flow is automatically supplied to one, two or all three cylinders depending on the force required.
The maximum working speed is three times faster than conventional presses with the same drives. As a result, further cycle time reductions can be achieved, particularly for cold extrusion presses, where the force requirement does not rise significantly until the end of the forging cycle. Various process sequences can easily be programmed and saved by the operator using an on-screen menu control system. In addition, integrated and highly flexible part handling ensures maximum productivity.
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COLD FORGING
SYSTEMS FOR INDIVIDUAL REQUIREMENTS. Because of the modular structure of Schulers hydraulic presses, these cold extrusion presses can be adapted to the range of parts to be manufactured, as well as other customer requirements (e.g. available die concepts, spacing between stations).
Bed and slide surface, die space, stroke, number of stations and spacing between stations are flexible in the press design. Ejector concepts, as well as their forces and strokes, are defined according to the parts being manufactured. Stroke limitations, whether fixed or adjustable, and die change equipment are integrated as required.
The drive configuration ensures that required working speeds are reached, and therefore the desired output is achieved. The adaptable press geometry offers design flexibility for installation of automation with a tri-axis transfer (for high output) or robots (for high flexibility).
THE ADVANTAGES Tight parts tolerances because of rigid press frame and design High-precision workpieces due to precise slide guiding and motorized height adjustable hard stroke limitations in the bed and below the individual forging stations Increased output performance due to RingValve technology Part-specific optimization of the press cycle by Dynamic Force Control (DFC) for high output Low die wear due to low-speed contact (programmable motion curve) Increased flexibility with more forging stations Individually programmable ejectors in the bed and slide
THE APPLICATIONS Long-shaft components such as: Drive shafts Axle shafts Transmission shafts Truck axles
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CASE STUDY
CUSTOMER: AUtOmOtIVE sUPPLIER
THE REQUIREmENts: Fully automated press line for manufacturing shafts weighing up to 25 kg. Extremely high flexibility needed the customer wishes to extend product range to non-automotive parts, such as large specialized screws.
THE SOLUTION: Schuler supplied one hydraulic five-station transfer press with Dynamic Force Control. Press capacity: 25,000 kN Slide stroke: 1,000 mm Production rate: 12 parts/min Part loading and separation Tri-axis Compact Mono Beam Transfer using hydraulic active grippers and turnover grippers Five die sets Die change equipment
Tri-Axis Compact Mono Beam Transfer.
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1 Bin tipper 2 Vibration hopper 3 Step feeder 4 Sorting scale 5 Loading station Tri-Axis Compact Mono 6 Beam Transfer 7 Safety device 8 Finished part conveyor 9 Finished part containers 10 Press 11 Die change arm 12 Control pendant panel
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COLD FORGING
Manipulators transferring the blank from the parts conveyor into the die.
ECONOMICAL FORGING WITH COMBINED DRAWING AND IRONING IN ONE STROKE. Hydraulic presses can form over almost unlimited stroke lengths under force, and therefore are well suited to wall ironing. In addition to traditional vertical forging systems, Schuler also offers horizontal presses. With ingenious integration of two die chambers in this design, the return stroke of the slide can also be used for forging, thereby increasing productivity.
THE ADVANTAGES High component quality in terms of accurate dimensions and shape, as well as surface quality Economical production with combined deep-drawing and ironing operations in one forging procedure No limits on component length due to unlimited working strokes of hydraulic press systems High output performance, particularly with horizontal press systems using two die chambers
THE APPLICATIONS Long, thin walled parts such as: Shock absorbers Hollow shafts CO2 cartridges
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WHETHER SHORT OR LONG NET SHAPE IS THE GOAL. As a rule, one ironing operation is sufficient for calibrating precise components. Long, thin walled parts are generated in one stroke by relatively large reductions in the wall thickness on presses with long stroke length and several ironing rings arranged consecutively. The blanks are pulled through the die with the punch. In one cycle, the wall thickness is reduced precisely to the required dimension, the ultimate shape is created and the surface is smoothed.
Blanks and cups are processed on the same machine without any return stroke.
MHS 800/800 MHS 1000/1000 MHS 1250/1250 MHS 1600/1600 2 8,000 2 2 10,000 2 2 12,500 2 2 16,000 2
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COLD FORGING
Die space.
COmpREssEd NAtURAL GAs. Today, more and more vehicles are driven with alternative fuels. The travel distance of gas-fueled vehicles depends significantly on the vehicle weight and the fill volume of the fuel tank. To deal adequately with both of these factors, it is necessary for the compressed natural gas (CNG) containers to withstand considerable internal pressure and also be
lightweight in design. Beginning with the blank, CNG containers are manufactured on Schuler machines in several drawing/ironing operations. A blank holder is integrated depending on the forging station. CNG CONTAINERS FROM BLANKS. Manufacturing CNG gas cylinder tanks from blanks offers many advantages. Blanks are easier and less expensive
to manufacture than seamless precision tubes. In addition, they have thinner bottoms compared to containers forged from a solid block. High surface quality is guaranteed by the integrated ironing process. Fully automated production processes and fast changeovers maximize productivity for the system.
THE ADVANTAGES Lower material cost of blanks as compared to precision tubes Lower weight than traditionally forged containers Larger container diameters are possible compared to traditional forging High surface quality
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COLD FORGING
KNUCkLE-JOINt pREssEs
EFFICIENCY, STEP BY STEP. Knuckle-joint presses are suitable not only for high-volume production of small components but also for producing a variety of shafts, due to the large range of slide strokes. The latest control systems make it possible to integrate the presses easily into fully automated production systems.
Knuckle-joint press MMK2-1000. Drive system for a knuckle-joint press.
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COLD FORGING
KNUCkLE-JOINt pREssEs
The variety of features and available functions such as bed and slide ejectors, blank feeding, transfer and die changes means that the systems can be used for specific applications or flexibly optimized for a wide range
of applications. The various designs that can be selected for kinematic motion of the slide enable these presses to be configured for warm forging as well.
THE ADVANTAGES High output rate Reduced forging speed Longer die life Wide range of applications
THE APPLICATIONS Parts for: Engines/transmissions Drive components Suspension components Fasteners Roller bearing elements
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KNUCkLE-JOINt PREssEs
CASE STUDY
CUSTOMER: AUtOmOtIVE sUPPLIER
THE REQUIREmENts: Supply a turnkey solution for economical series production of steering system components in the automotive industry.
tHE SOLUTION: Schuler supplied a knuckle-joint press: Press force: 8,000 kN Ram stroke: 450 mm Production rate: 50 parts/min 3-axis servo transfer system Automatic feed system with bin tipper Die lubrication system Die change equipment
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COLD FORGING
Servo motor.
THE ADVANTAGES Increased output rates Individually programmable ram speeds and motion sequences Ability to optimize the forging process High component quality and long die life Ability to adapt slide movement to the transport sequence Sensitive tryout operation possible Optimized energy consumption
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COLD FORGING
FORMMAstER
FormMaster.
Nowadays, shaped parts and fasteners are manufactured almost exclusively by forging processes. These processes combine high productivity with dimensional accuracy, for optimum grain flow and surface finish. At the same time, requirements for increased product quality, small batch sizes, complex parts geometries and just-in-time delivery conditions present production and automation systems with significant challenges.
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COLD FORGING
FORMMAstER
With FormMaster multi-station presses, Schuler offers presses that meet these requirements. Designed in dialog with operators, production
and maintenance specialists, toolmakers and designers, the FormMaster offers high productivity and maximum availability.
THE ADVANTAGES Optimum ergonomic access to die space High level of user friendliness Very good visibility of the die space Reliable servo transfer with transport parameters adjustable from the control panel Ease of maintenance Part transport monitoring Machine requires 30% less floor space Integrated die cooling/lubrication system
THE APPLICATIONS Various parts from the fitting, joining, automotive industry, tools and hardware
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COLD FORGING
OptImUm pROdUCtION CONdItIONs. The servo drive enables the slide movement of the FormMaster horizontal cold header programmed for the specific parts. Even with a wide range of parts, it's possible to optimize the kinematics to the requirements of the forging process. Achieving optimum conditions for part transport with long parts, setting an optimum forging speed for part quality or to reduce die wear and producing critical extruded parts can all be done with high stroke rates and throughput.
THE ADVANTAGES High efficiency with optimized process Great flexibility due to adaptable slide movements Optimum ergonomic working position Very good visibility of the die space Reliable NC transfer with adjustable transport parameters Adapted forging speed for critical forgings Optimum clearance for long forgings Servo wire feed for high flexibility and accuracy
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WaRm FORGING
At a GLaNCE
Systems for warm forging offer advantages to produce components with large dimensional changes and high precision. Prior to the first forging station, the components are heated to a temperature between 700C and 950C, depending on the application. The flow stresses are much lower than in the case of cold forging. Also, there is less distortion and scale formation than in hot forging. Mechanical presses with eccentric or knuckle-joint drives are used in this temperature range. A great advantage to this process is that the die is almost entirely closed, and no flash is formed. The tight tolerances and lack of surface decarburization allow net-shape geometries or very small machining allowances to be achieved, thereby reducing the amount of material that needs to be used. The lower temperature compared to hot forging also requires less energy.
ECCENtRIC PREssEs ECCENtRIC PREssEs WIth SERVODIRECt TEChNOLOGy KNUCkLE-JOINt PREssEs Information about knuckle-joint presses can be found starting on page 23 KNUCkLE-JOINt PREssEs WIth SERVODIRECt TEChNOLOGy Information about knuckle-joint presses with ServoDirect Technology can be found starting on page 26
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WaRm FORGING
ECCENtRIC pREssEs
SHORT CONTACT TIMES. Eccentric presses are well suited for warm forging due to the sinusoidal motion sequence, as there is a short contact time and sufficient non-contact time available for die cooling. This series of presses can be configured with 1 or 2-point slide attachment, and offers a wide range of rated press forces, with the ability to achieve long stroke lengths of 1,000 mm or even more. The generously sized die space permits the use of heavily reinforced dies. The flexible controls can incorporate a wide range of peripheral devices in order to make a fully automated production line.
THE ADVANTAGES Long stroke length High output rates Minimum contact times Extended non-contact times for die cooling Long die life Large die space Tight component tolerances and high component quality Optional servo drive
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WaRm FORGING
ECCENtRIC pREssEs
The classic eccentric drive in its compact design is particularly suitable for use in warm forging. The drive kinematics, which can optionally be configured with a servo drive, combined with the high-performance bed and ram ejector systems, offer the best conditions for reliable workpiece handling and high output. It is also possible to integrate with multiple feeder and transfer devices. These presses can also be used successfully for cold forging and precision forging applications.
THE APPLICATIONS Parts for: Engines/transmissions Drive components Suspension components Fasteners Roller bearing elements
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ECCENtRIC PREssEs
CASE STUDY
CUSTOMER: AUtOmOtIVE sUPPLIER
THE REQUIREmENts: Deliver a fully automated line for warm forging production of driveline components. THE SOLUTION: Schuler delivered an eccentric press: Press force: 20,000 kN Ram stroke: 800 mm Output rate: 38 parts/min Induction heating with parts feed and temperature monitoring, with a system for gating-out parts 3-axis servo transfer system Cooling section Extensive die, cooling and lubrication accessories
Fully automated line for warm forging.
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1 Bin tipper 2 Vibration hopper 3 Step feeder 4 Scale with sorting device 5 Lateral transport conveyor 6 Pre-graphitizing station 7 Graphite tank 8 Induction heating 9 Die lubrication tank 10 Conveyor for colder part removal 11 Container for colder parts 12 Operating panel 13 Protective device on the infeed side 14 Transfer system 15 Press 16 Protective device on the exit end 17 Die change arm 18 Cooling section 19 Finished parts container
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WaRm FORGING
THE ADVANTAGES High efficiency with throughput with optimized slide motion Best component quality even with complex parts Great flexibility due to adaptable slide movements Best energy efficiency compared to conventional presses Maximum process reliability Long stroke Optimized timing to handle long parts Start/stop operation now possible Setting up dies with reduced speed
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This type of press is particularly suitable for components with an elongated shape, which have a high energy requirement due to their long forging travel. The combination of the eccentric drive and ServoDirect Technology permits increased productivity levels, because the slide kinematics can be optimally adapted to the automation.
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Movement profile with optimized slide curve Movement profile of conventional eccentric drive Increased output with the same transport timing due to the ability to program slide speed for a faster forging process in the die.
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hOt FORGING
At a GLaNCE
Schuler offers a wide range of products for hot forging that includes hammers, screw and crank presses, as well as hydraulic forging presses to support a variety of applications. In hot forging, the starting material is heated to a temperature at which recrystallization proceeds in parallel with forging.
DOWN stROkING hammERs LINEaR hammERs WIth SERVO TEChNOLOGy COUNtERbLOW hammERs SCREW PREssEs WIth DIRECt DRIVE
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The material does not undergo work hardening, and can be formed almost without restrictions. The choice of forging process enables the grain profile in the component to be adapted to the requirements. This leads to improved dynamic component properties.
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HOt FORGING
MAXIMUM EFFICIENCY EVEN IN SMALL-TO-MEDIUM BATCH SIZES. Down stroking hammers are used for many kinds of applications, and are particularly suitable for small-to-medium sized parts. The sturdy, monoblock U-frame design, in conjunction with precise guides with a large surface area, provides high forging accuracy. The hydraulic down stroke drive permits high stroke rates combined with minimum contact times. The modern control system permits precise adjustment of the impact energy and stroke rate.
THE ADVANTAGES High stroke rate Minimum contact times Low operating costs Simple operation Guides with large surface area Universally applicable
THE APPLICATIONS Chassis components Flanges Connecting rods Turbine blades Hand tools
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ADDITIONAL EQUIPMENT Automation Anvil bed heating Anti-vibration installation Acoustic insulation Customer-specific custom solutions
1 Drive head 2 Piston rod 3 Slide 4 Upper die 5 U-frame 6 Lower die
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CASE STUDY
CUstOmER: AN aUtOmOtIVE sUPPLIER
THE REQUIREmENts: Automatic forging cell for economically efficient production of engine and transmission parts, in addition to other components. The components have a single part weight of up to 4 kg and are intended to be forged as a multiple part. THE sOLUtION: Automatic hammer line with down stroking hammer KGH 4.0B. Part handling is performed by robots using special grippers. This makes it possible to use a safe forging process in the hammer. FULLY AUTOMATED FORGING CELL
1 Furnace 2 Part feeding conveyor belt 3 Down stroking hammer KGH 4
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HOt FORGING
MAxImUm ImpACt ACCURACY wItH LINEAR dRIVE. The newly developed and patented drive system for down stroking hammers impresses with maximum impact accuracy, for highly sensitive forging processes or demanding customer requirements.
The non-contact linear drive is almost wear-free, extremely dynamic and offers the possibility of flexible stroke control. This means the machine can be adapted to the requirements of the forging process with the maximum degree of effectiveness.
THE AdVANtAGEs More energy efficient than conventional hammers Increased machine availability due to low-maintenance drive Non-contact drive does not cause any mech./hydr. wear Flexible stroke control A bility to optimize the forging process Setup and press functions can be carried out without additional drive elements High repeat accuracy of the slide kinematics Improved automation capability Higher impact frequency
THE APPLICATIONS Chassis components Flanges Connecting rods Turbine blades Hand tools
ADDITIONAL EQUIPMENT Automation Anvil bed heating Anti-vibration installation Acoustic insulation Customer-specific custom solutions
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HOt FORGING
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1 Drive head with linear drive 2 Slide 3 Upper die 4 U-frame 5 Lower die
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hOt FORGING
COUNtERBLOW HAMMERs
FOR LARGE FORGED PARTS. BCH counterblow hammers are predominantly used for manufacturing large and ultra-large forgings. The high impact energy and tonnage of the hammer dies, moving in opposite directions, permits precision forming of large forgings.
THE AdVANtAGEs Extremely high impact energy and tonnage High reliability and availability High stability of the overall structure High precision with large forgings Hydraulic tup coupling Long stroke for accessibility
THE APPLICATIONS Crankshafts Turbine blades Driveline and chassis components for cars and trucks Flanges and disks
ADDITIONAL EQUIPMENT Die change systems Tup heating systems Ejector systems Spraying systems
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TEChNICaL DEtaILs
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Counterblow hammers with hydraulic drives are particularly well suited to the medium tonnage range. There is no need for an extensive compressed air system.
1 Drive head 2 Piston rod 3 Upper tup 4 Upper die 5 Upright 6 Tup support 7 Lower die 8 Lower tup 9 Hydraulic tup coupling 10 Buffer
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1 Crown 2 Upper tup 3 Upper die 4 Upright 5 Tup support 6 Lower die 7 Lower tup 8 Hydraulic slide coupling 9 Buffer
DG 140
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This series employs the proven pneumatic drive concept. It allows very large forging energy levels to be achieved. The sturdy design of the uprights, together with a solid guide system, ensures high precision during forging.
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COUNtERbLOW hammERs
CASE STUDY
CUSTOMER: COmPONENts INDUstRy
THE REQUIREmENts: Economical production of large crankshafts with a component length up to four meters and weighing up to 3,000 kg each. THE SOLUTION: Schuler designed and manufactured a semi-automated forging line, based upon the DG 80H counterblow hammer. The entire forging line is equipped with an advanced control concept for optimizing the process parameters and material flow, based on an innovative logic function. SEmI-AUtOmAtEd fORGING LINE wItH COUNtERbLOw HAmmER ANd tRImmING/CALIbRAtING pREss
1 Manipulator 2 Storage area 3 Furnace 4 Descaling 5 Drop machine 6 Counterblow hammer 7 Trimming and calibrating press Production of large crankshafts up to 3,000 kg. Counterblow hammer with a rated capacity of 800 kJ.
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hOt FORGING
HIGH fLExIbILItY. Thanks to almost 120 years of experience in building screw presses with continuous developments, there is practically no drop forging that cannot be manufactured using a screw press. As far back as 1936, the conventional friction drive was superseded by the
friction roller drive and, subsequently, direct drive. In 1963, reliable threephrase synchronous motors with rapid permitted switching frequencies opened the door to a new and ideal drive system for screw presses. In this direct drive, the torque from the drive motor is transmitted to the screw
without intermediate drive components, wear parts or energy losses. This drive concept represents the optimum design solution for a screw press drive in terms of robustness, reliability, maintenance and efficiency.
THE AdVANtAGEs Wide range of parts High repeat accuracy High reliability High flexibility Maximum efficiency
THE APPLICATIONS Forgings for the automotive industry and commercial vehicles such as crankshafts, axles, connecting rods or transverse links Surgical instruments as well as turbine components Fittings, flanges, hand tools, cutlery
ADDITIONAL EQUIPMENT Ejector in the bed and slide Die change systems Customer-specific solutions
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TEChNICaL DEtaILs
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The body of the press in the PA series is a monoblock design. An additional torque limiting clutch is used for overload protection in the PAR series.
This system makes it possible to implement a higher working energy on the press, which is necessary for large forming distances. Small components
made from non-ferrous metals and requiring high precision can be forged efficiently on type PA and PAR screw presses with direct drive.
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TEChNICaL DEtaILs
The medium PSM/PSH series are produced as a two-piece casting held together by four tie rods. In the PSM
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series, once a defined forging force has been reached, the tie rods absorb surplus energy protecting the press against overload. In addition, the PSH series features a hydraulic overload protection system. This system allows the press to be equipped with a higher working energy, which is necessary when large forgings are involved. The series has a frequency drive. This not only allows precise control, but also delivers improved efficiency and better repetitive accuracy.
1 Drive 2 Crown 3 Screw 4 Ram 5 Frame 6 Upper die 7 Die change arm (option) 8 Lower die
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1 Flywheel 2 Motor 3 Crown 4 Ram 5 Upper die 6 Upright 7 Lower die 8 Bed
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Screw press with direct drive type PZS 900f for manufacturing heavy forgings.
The frame of PZS presses in this series is a four-piece casting held together by four tie rods. The drive comes from several motors linked via a bull gear to
the external diameter of the flywheel. The press force is limited by a slipping clutch in the flywheel.
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CASE STUDY
CUSTOMER: MaNUFaCtURER OF hEaVy DUty tRUCk ENGINE COmPONENts
THE REQUIREmENts: System for automated production of truck crankshafts and truck front axles.
THE SOLUTION: Schuler supplied a complete, fully automated forging line. A PZS 900f screw press with direct drive is used as the main forging machine. All necessary process steps such as rolling, pre-forming forging, finish forging, trimming, twisting and calibrating are accomplished in the line.
Screw press with direct drive type PZS 900f in operation.
1 Rotary hearth furnace 2 Descaling 3 Reducer roll 4 Screw press with direct drive PZS 900f 5 Robot/manipulator 6 Trimming and calibrating press 7 Twister 8 Calibrating press 9 Cooling section
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CRANk pREssEs
SpEEdFORGE. High-performance crank presses are particularly well suited to fully automated production of high volume forgings. The frame and drive system are designed for high load and production precision. An extensive range of equipment including material feed, transfer system and finished part removal, spraying system and die change makes it possible to adapt the presses to various production jobs with ease. These presses can be efficiently used both for steel and non-ferrous materials.
THE ADVANTAGES High production speed Fully automated parts handling High production accuracy High rigidity Efficient series production
ADDITIONAL EQUIPMENT Ejector in the bed and slide Servo transfer Feeder Die change system Spraying system
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THE ADVANTAGES Reduced contact time Reduced die wear More time for die cooling and part transport
tHE APPLICATIONS Chassis components Flanges Drive components Bearing races Gear blanks
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CRANk pREssEs
1 Drive 2 Crown 3 Crank shaft 4 Upright 5 Ram 6 Ram ejector 7 Die holder 8 Transfer 9 Die 10 Bed ejector 11 Bed
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Stroke
Time
Movement profile of servo press, e.g. for steel Movement profile of servo press, e.g. for aluminum Movement profile of conventional crank drive Installation of a forging press with ServoDirect Technology. ServoDirect Technology allows the slide motion to be programmed individually.
DIRECt dRIVE. In forging presses with ServoDirect Technology, several torque motors act on a main shaft via a step-down gear unit. These types of presses are suitable for single-stroke operation as well as forging in continuous operation.
The stroke rate and forging speed can be optimally adapted to the part. Production output levels are increased by shorter pressure contact times and a corresponding lower heat input into the dies.
THE ADVANTAGES High efficiency with optimum productivity levels Great flexibility due to adaptable slide movements Rigid configuration with triple bearings for the crankshaft Short pressure contact times and low heat input Wear-free single-stroke operation is possible Immediate access to the die installation space, for example in tryout mode Station to station part handling with minimal speed
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Stroke
Time
Movement profile of DualDrive Movement profile of conventional crank drive 1 DualDrive 2 Crank shaft 3 Flywheel drive 4 Flywheel Reduced pressure contact time with DualDrive.
DUALDRIVE TECHNOLOGY. The DualDrive concept for crank presses makes it possible to move through the top dead center position at a very low ram speed, and move through the bottom dead center position at a very high ram speed. The forging press is equipped with two drives for this kind of high-performance.
With this drive concept, called DualDrive, it is possible to vary the ram speeds between 6 and 12 strokes/min. in the TDC area and between 60 and 120 strokes/min. in the BDC area. As a result, the die contact times can be cut to a minimum, thereby extending the die life. Also, the time available for die cooling and for parts
1. A conventional main drive with flywheel, clutch/brake combination with freewheel and planetary gear unit. 2. A controlled auxiliary drive for the sections in which no forging takes place.
transport is longer. This means the productivity of the press can be increased significantly by full capacity utilization. Output rates of up to 40 parts/min are possible, depending on the part size.
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CASE STUDY
CUSTOMER: AUtOmOtIVE COmPONENts INDUstRy
THE REQUIREmENts: Fully automated production system for flanges with high output. THE SOLUTION: Schuler supplied a complete production line comprising part feed, induction heating system, PK 3150 crank press with DualDrive Technology, hydraulic ejectors and complete automation system as well as part removal with controlled cooling. The package also included die holders, dies and a die change system. The forging line manufactures various flanges with a productive output of 30 parts/min, in a flash-free production process involving five forging stations.
PK 3150 with DualDrive Technology. A forging glows in the die.
1 Part feeder 2 Induction furnace 3 Loader 4 Crank press with automation 5 Conveyor belt 6 Cooling section
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THE ADVANTAGES Ease of operation because of uniform graphical user interface with touch screen Monitoring functions for parameters affecting quality, such as impact energy, part thickness, impact force, part temperature Required impact energy can be applied precisely Visualization in almost every customers language Access to machine documentation, circuit diagrams and fluid diagrams Remote maintenance and diagnosis Interfaces for external data storage as well as print function, including integration in a customers network Control loops to ensure that process parameters are observed, especially for screw presses
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ADDITIONAL EQUIPMENT MDA-Machine Data Acquisition Barcode scanner Pyrometer for part temperature Central control for forging cells with central data storage and data management Interlinking interfaces and, if required, control functions to customers forging peripherals Energy feedback into the power system when operating screw press with frequency inverter Heating with control loops for top and bottom Customer-specific special functions
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Stroke
Time
Movement profile for clamping Upsetting profile with reduced forging speed Upsetting profile with conventional eccentric drive Upsetter with ServoDirect Technology in production. ServoDirect Technology allows the clamping and upsetting movements to be programmed individually.
MAxImUm pROdUCtION OUtpUt. The upsetter with ServoDirect Technology permits maximum production output and makes it possible to optimize forging parameters for the material in the forging process. The upsetter with ServoDirect Technology is operated with two separate servomotors. At the same time, the movements of
the clamping and upsetting slide can be set independently from one another. This offers the advantage of adapting the movement kinematics flexibly to the forging process. Furthermore, the shortest pressure contact times can be achieved in the clamping and upsetting work sequence.
THE ADVANTAGES Independent movements of the clamping slide and the upsetting slide due to two servo drives High output performance Double overload protection with force and torque limitation Energy efficiency due to current consumption at different times Complex components
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PREss SYstEms. According to the requirements Pull Down (MHFU-series) as well as Push Down concepts (MHFT-series) in two or four column design can be provided. Beside the need of a deeper foundation pull down presses are offering plenty advantages. Less tendency of swing, clear forging area with excellent accessibility and drive system below floor level is protected against contamination.
Passage width 1,400750 1,600850 1,800 1,000 2,000 1,100 2,3001,200 2,5001,400 3,5001,550 4,000 1,800 4,5002,000 5,0002,200 [mm]
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PROVEN dRIVE SYstEm. The Modified Sinusoidal Direct drive System (PMSD) gives presses an extremely high cycling frequency in a shock free manner, because there are no operating valves in the main lines of the system. This drive and control system is designed for low maintenance requirements and high availability. TURNkEY SOLUtIONs fOR OpEN dIE FORGING. Forging Manipulators integrated with the forging press complete the equipment of modern forge shops with optimized productivity. They provide fast and precise positioning of the forging and allow automatic operation and repetition of proven forging methods. Manipulators are also suitable as Master Carrier when forging heavy forgings with crane assistance. Pop Up Turntables arranged between the manipulator and press assist charging by mobile chargers and are used to rotate forgings.
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By forming a strategic partnership with Pahnke for open die forging, Schuler broadens its capabilities with a well known and experienced name in the industry. Together, we provide our customers a broad range of products and services, even for large scale and complex projects. Our goal is to ensure a competitive advantage for our customers to achieve profitable production systems producing high quality open die forgings.
THE ADVANTAGES High productivity Energy efficient drive techno logy Excellent uptime and availability
tHE APPLICATIONS Slabs Different kinds of shafts Sleeves Rings Special forgings
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FORGING LINEs wItH HYdRAULIC pREssEs. The working sequences before and after the actual forging are frequently performed on hydraulic presses. On hydraulic pre-form presses, pre-forms are generated so that there will be a mass distribution appropriate for the die. Having a pre-form with a good structure reduces the amount of material used and also reduces the forming forces required during forging. The die life is improved. Following die forging, the flash is trimmed off and any required piercing and coining work is performed on hydraulic trimming and calibrating presses. These working sequences can either be combined in one die or performed consecutively in several stations. Hydraulic presses are the main units used for manufacturing complex parts such as ring blanks, aluminium wheels or railway wheels.
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HIGH fORCEs ANd LONG wORkING tRAVEL dIstANCEs. Hydraulic forging presses are used wherever high forces and long working travel distances are required. This is revealed in numerous special applications up to press forces of 300,000 kN and working travel distances of 4 m. Examples include hot forging presses, piercing presses and presses for partial forging of fittings and thick-walled pipes.
tHE APPLICATIONS Aluminum wheels Railway wheels for cars Railway wheels for engines Fittings for pipelines Thick-walled pipes Rail ends Large flanges and brake disks (pre-forming) Crank shafts (calibrating) Axle parts (calibrating) Seamless rings as the precursor for: Bearing shells Crown gears Flanges Blade carriers for jet engines Various highly stressed structural elements
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FORGING ANd ROLLING RAILWAY WHEELS. Railway wheels are manufactured in three forging stages before they are processed further with machining. First, the heated billet is pressed into a diskshaped pre-form on a pre-form press. Next, this blank is rolled into the shape of a wheel on a rolling machine. Last, the rolled wheel is shaped in a calibrating press and a hole is pierced in the hub. Hydraulic presses with press forces up to 100,000 kN are used for pre-forging the wheels. As a rule, press forces from 20,000 to 50,000 kN are required for shaping and piercing.
THE ADVANTAGES High press forces achieve more accurate pre-forging, reducing rolling work Weight savings due to greater accuracy High output
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HYdRAULIC pREssEs fOR fORGING RING bLANks. When manufacturing seamless rings, the first forging operation is forging the ring blank. Ring rolling lines turn these into the precursors for bearing shells, crown gears, flanges, turbine disks for jet engines and various highly stressed structural elements. Hydraulic presses are particularly well suited for forging ring blanks: High forces, long strokes and an unlimited rated capacity are the features needed for efficient ring blank forging. Either highly flexible lines or multi-station processes with optimized output are used, depending on the depth of the product range and/or the required output rate. Centering devices, swivel arms, robots and manipulators guarantee suitable parts and die handling.
THE ADVANTAGES High forces for extremely large parts High flexibility and high output rates Proven press concepts Different forging processes adapted to the parts Coordinated die processes, in-house die and process expertise
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Step 520
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PROCESSES DEPENDENT ON THE PRODUCT. The required part geometry and a suitable grain flow are provided by different forging processes. Ring blanks for simple parts are manufactured by open die upsetting followed by pre-piercing and piercing. Complex geometries are achieved by forging and pre-piercing in a die. Pre-piercing guarantees a symmetrical grain flow in the part and has a positive effect on the mechanical properties of the finished product. Each process requires a precisely configured line with the necessary level of flexibility for the required output rate. The short cycle time of the press allows the ring blank to be further processed before it cools. Different materials present the forging line with different challenges. Low-alloy steels can be formed relatively easily, while exotic materials such as nickel-based alloys, Inconel, titanium and aluminum alloys require process parameters that can be adjusted or even varied during the forging operation, such as adjustable profiles for the forging speed.
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FORGING ALUmINUm wHEELs. Weight savings achieved in the driveline are leading to more energy efficient vehicles. In addition, reducing the wheel weight in trucks can allow for a payload increase of up to 500 kg, depending on the number of wheels, for the same gross vehicle weight. In addition, the ability to polish the surface to a mirror-like finish makes the hearts of some truck drivers beat faster. These requirements are met by forged aluminum wheels. Hydraulic presses with high press forces make it possible to forge aluminum wheels with superior properties: Improved mechanical properties, lighter weight, good chemical resistance, and almost unlimited design options. Turnkey systems including the presses, a saw for the billets, heaters, automation and die change devices make it easy to start forging aluminum wheels, or to extend an
Turnkey system for manufacturing aluminum wheels.
existing production facility. Line controllers make sure the complex systems operate reliably.
THE ADVANTAGES Concentrated high press forces Proven press concepts High precision and quality of forged wheels High output rates Forging processes adapted to the part geometry Complete lines from a single source
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AdAptEd fORGING pROCEssEs fOR tHE pROdUCtION Of ALUmINUm wHEELs. The design and geometry of the forged wheel, as well as the required quantity, influences the type of system selected for production. Simple wheel geometries without a forged rim face, such as truck wheels, are forged in one station. The following station carries out the trimming and flaring of the rim. A similar process is used for small quantities, in which the design of the rim face is completed by machining. For rims with a profiled face, press lines comprising typically three to four presses are used. The parts are either forged with one heat in three to four stations or with intermediate heating. Single or double-action presses make it possible to forge the rim face precisely. The surface is either left unfinished (as forged) or machined, depending on the quality required.
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CASE STUDY
CUSTOMER: SUPPLIER tO aUtOmOtIVE aND tRUCk INDUstRIEs
THE REQUIREmENts: Line for economical aluminum wheel manufacturing for cars and pickups. THE SOLUTION: Schuler supplied two manufacturing cells, each based on presses with 70,000 kN press capacity. The aluminum wheels are forged in one stroke. High-performance ejectors are installed in bolster and slide to make sure the parts are unloaded safely from the die. The wheels are then flared on a press with 8,000 kN press capacity. The proper operating conditions of the dies are ensured by a lubricating and cooling system consisting of a lubricant conditioning device and linear manipulator with rotary head. Both oil-based lubricants and water-based lubricants can be used. Part handling inside the cell is done by a six-axis robot designed for forging. Short cycle times are achieved by double grippers. Hydraulic clamps with internal cooling and a tandem die change cart are provided for quick and safe die changes.
Hydraulic press with 70,000 kN press capacity in production. Forged part and finished wheel.
1 Hydraulic forging presses with 70,000 kN capacity each 2 Flaring pesses with 8,000 kN capacity each 3 Robot with double-tooling 4 Lubrication manipulator with rotating head 5 Die change cart
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RING ROLLER
Step 520
3.70
1.85
TAILOR-mAdE fORGING ANd ROLLING pROCEssEs fROm SCHULER. These machines make it possible to manufacture seamless rings according to their specific required properties. The seamless rings are used on engine casings, bearing
shells, blade carriers and different structural elements. Advanced features offered by Schuler, such as simultaneous punching, achieve optimized flow of special products.
THE AdVANtAGEs Of RING ROLLER Reliable technology proven for decades in forging environments Special design for production of small and large rings on the same ring roller Quick tool change solutions to reduce machine downtime
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WHEEL ROLLER
TURNkEY mACHINEs fOR mANUfACtURING wHEELs EffICIENtLY. Schuler special equipment configurations can fulfill all customer requirements for a complete process starting from the continuous casted material to the finished wheel
for the most economic production of wagon, locomotive, and high speed wheels. High press forces linked to precise control systems ensure low material consumption.
THE AdVANtAGEs Of wHEEL ROLLER High accuracy due to rigid machine design All tool axles driven (main and support drives) Continuous cooling during loading /unloading for less wear and increased tool life I nternal torque zeroed for less abrasion and extended tool life Extended life time of shafts and bearings due to wellsized units
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WhEEL ROLLER
CAsE stUDY
CUstOmER: NEW sUPPLIER FOR RaILWay INDUstRy
THE REQUIREmENts: Production of forged wagon, locomotive and high speed wheels with an output up to 72 wheels per hour, with minimum material consumption and high availability. tHE sOLUtION: Schuler supplied the complete forging line with both process and die technology. Large hydraulic presses, designed with external billet centering and special guiding in the tooling, prepare wheels for the newly developed wheel roller to produce precision forged high-speed rail wheels. Quick and easy change-over of the entire line is supported by double die change carriages. The line control ncludes integrated process simulation software to automate the sequence of operations of the railway wheels. This, in combination with the high press forces, leads to approximately 10% reduction in material consumption as compared to current systems in the market.
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At a GLaNCE
SCHULER WORLDWIDE. As the technological and global market leader in metal and plastic forming, Schuler offers cutting edge presses, automation, dies, process know-how and services for the entire metalforming industry and lightweight car body construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industry. Schuler is the market leader in coin minting technology and supplies systems solutions for the aerospace, railway and large pipe industries. With 5,500 employees, Schuler is represented in 40 nations around the world. The Austrian ANDRItz Group holds a majority share in Schuler.
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LOCatIONs
Mechanical presses for cold and warm forging Schuler Pressen GmbH Bahnhofstrae 41 73033 Gppingen | Germany Phone +49 7161 66 -307 Fax +49 7161 66 -729 Schuler Service Phone +49 7161 66-628 Schuler Service Fax +49 7161 66-626
Schuler Group Headquarters, Gppingen.
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[email protected] www.schulergroup.com/forging
68753 Waghusel | Germany Phone +49 7254 988-226 Fax +49 7254 988-490 Schuler Service Phone +49 7254 988-325
Mechanical presses for hot forging Schuler Pressen GmbH Werk Weingarten Schussenstrae 11 88250 Weingarten | Germany Phone +49 751 401-2211 Fax +49 751 401-952211 Schuler Service Phone +49 751 401-2244 Schuler Service Fax +49 751 401-2670
Schuler Service Fax +49 7254 988-361 Service center forging hammers Schuler Pressen GmbH Servicecenter Remscheid Industriegebiet Bergisch-Born Am Weidenbroich 1a 42897 Remscheid | Germany Schuler Service Phone +49 2191 95199-20 Schuler Service Fax +49 2191 95199-81
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SCHULER ONLINE With approximately 5,500 employees around the world at our own sites and in agencies, we are ready to serve you locally in 40 countries. We look forward to hearing from you. You can find an overview of our sites and contact information at www.schulergroup.com/plant_locations.
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1 Germany 2 France 3 Great Britain 4 Italy 5 Poland 6 Switzerland 7 Slovakia 8 Spain 9 Russia 10 Brazil 11 China 12 India 13 Mexico 14 Thailand 15 USA
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GERMANY
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Schuler Service offers a tailored portfolio of services covering the entire life cycle of your equipment.
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Over 900 service employees worldwide provide expert support around the clock in close cooperation with you our partners. Our main priority is always to ensure the ultimate productivity and safety of your production equipment in order to secure your companys continued success. With over 170 years of experience and expertise, we can guarantee the best possible support for the operation of your machines and not only those supplied by Schuler, but by all other manufacturers. Whatever the situation, Schuler Service has the right solution for your specific needs.
Components and Accessories: Spare parts and spare part packages Maintenance kits Repair parts Replacement parts Project Business: Modernization Retrofits Refurbishment Machine relocations Special Services:
OUR SERVICES FOR YOU. Technical Customer Support: Machine inspections Safety inspections Preventive maintenance Repair Repair welding Production support
Service contracts Hotline and remote service Training Tailored customer training Optimizing plant & processes Consulting Used Machinery: Purchase and sale Evaluation
SCHULER ONLINE Want to know more about our full range of services? Simply scan the QR code with the camera of your smartphone or tablet. www.schulergroup.com/service
www.schulergroup.com/forging Find out more. Simply scan the QR code using the camera of your smartphone or tablet.
Mechanical presses for cold and warm forging Schuler Pressen GmbH Bahnhofstrae 41 73033 Gppingen | Germany Phone +49 7161 66-307 Fax +49 7161 66-729 Schuler Service Phone +49 7161 66-628 Schuler Service Fax +49 7161 66-626 Service center forging hammers Schuler Pressen GmbH Servicecenter Remscheid Industriegebiet Bergisch-Born Am Weidenbroich 1a 42897 Remscheid | Germany Schuler Service Phone +49 2191 95199-20 Schuler Service Fax +49 2191 95199-81
Mechanical presses for hot forging Schuler Pressen GmbH Werk Weingarten Schussenstrae 11 88250 Weingarten | Germany Phone +49 751 401-2211 Fax +49 751 401-952211 Schuler Service Phone +49 751 401-2244 Schuler Service Fax +49 751 401-2670
Hydraulic presses Schuler Pressen GmbH Louis-Schuler-Strae 1 68753 Waghusel | Germany Phone +49 7254 988-226 Fax +49 7254 988-490 Schuler Service Phone +49 7254 988-325 Schuler Service Fax +49 7254 988-361
[email protected] www.schulergroup.com/forging