The entire world of forging

ForMinG The FuTure

Forming the Future

Put it into motion. Forging with Schuler. For over 170 years, the name Schuler has been synonymous with innovative technologies, quality and customer-oriented service in forging technology. Today, you can find Schuler all over the world, wherever forging systems are used safely and efficiently in production. This claim is backed by more than 5,000 employees at facilities in Europe, the USA, Mexico, Brazil, India, China and Russia. Recent integration of Mller Weingarten AG and the Bch brand strengthens the technological leadership of the entire Schuler Group. 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.

Contents

FORGING PROCESSES 1.1 Processes 1.2 Temperature ranges

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PROCESS AND DIE DEVELOPMENT 2.1 Process development 2.2 Die design 2.3 Die lubrication and cooling devices 2.4 Part feed and transport sequence analysis

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SYSTEMS FOR COLD FORGING 3.1 Hydraulic cold extrusion presses 3.2 Hydraulic ironing presses 3.3 Hydraulic presses for manufacturing CNG gas cylinder tanks 3.4 Horizontal multi-station presses for forging of wire 3.6 Multi-station presses with link drive

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SYSTEMS FOR WARM FORGING 4.1 Multi-station presses with eccentric drive 4.2 Multi-station presses with link drive

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SYSTEMS FOR HOT FORGING 5.1 Short-stroke hammers 5.2 Counterblow hammers 5.3 Screw presses 5.4 Crankshaft forging presses 5.5 Multi-station presses with eccentric drive 5.6 Open die forging systems in cooperation with PAHNKE 5.7 Hydraulic forging presses 5.8 Hydraulic presses for forging ring blanks 5.9 Hydraulic presses for forging aluminum wheels GLOBAL SERVICE

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IN PRACTICE Economic Efficiency From Small Presses to Large Turnkey Solutions

We offer custom solutions for all forging requirements whether our customers need a small press for manual operations or are looking for a large turnkey solution. We are also competent partners for modernization, modification or performance enhancement projects.

Forging places high requirements on production systems and automation for enhanced product qualities, small batch sizes and just-in-time delivery. Rely on the comprehensive knowhow of Schuler as a leading system supplier of cold, semi-hot and hot forming equipment.

Small or large forgings, technical challenges or precision forgings, we support our customers with comprehensive component engineering, from methods planning and tool & die making to commissioning of your forging line.

Manual short-stroke hammer for special forgings.

Automated screw press cell.

FormMaster optimally suited also for large batch volumes.

Turnkey solution for high-volume production of aluminum rims.

Forging Processes

Processes Temperature ranges

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Forging Processes

Processes

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.

Reduction.

Full forward extrusion.

Ironing.

Backward extrusion.

Lateral extrusion.

FORGING PROCESSES Processes

CLOSED DIE FORGING. CLOSED DIE FORGING is a forging process in which dies move towards each other and covers 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.

Closed die forging.

Upsetting.

Piercing.

Open die forging.

Trimming.

Processes FORGING PROCESSES

Forging Processes

Temperature ranges

Increasing degree of deformation Increasing dimensional accuracy

Hot forging > 950 C

Closed die forging Forging ring blanks Upsetting Open die forging Extrusion Piercing / trimming

Warm forging 750 C 950 C

Extrusion Upsetting / Setting Piercing

Cold forging Room temperature

Extrusion Ironing Upsetting / Setting Reduction Piercing

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 Temperature ranges

Process and die development

Process development Die lubrication Cooling device / Part feed and transport sequence analysis

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Process and die development

Process development

We offer the entire process development from a single source, including consulting and training services. 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.

Process development

Die design

Part feed and transport sequence analysis

Selection of the press concept

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PROCESS AND DIE DEVELOPMENT Process development

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.

PROCESS PLAN FOR TRIPOD HOUSING PRODUCTION Warm forging

Cold forging

Sequence development

Process development PROCESS AND DIE DEVELOPMENT

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Process and die development

Die lubrication

DIE DESIGN. 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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Ejector pin Thrust piece Pneumatic spring Inner punch Outer punch Spraying ring Die Reinforcement Counterpunch Thrust piece Ejector pin

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PROCESS AND DIE DEVELOPMENT Die lubrication

Process and die development

Cooling device / Part feed and transport sequence analysis

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.
Die cooling and lubrication systems for warm and hot forging.

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

Cooling device / part feed and transport sequence analysis PROCESS AND DIE DEVELOPMENT

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CASE STUDY Process and die development

THE CUSTOMER Construction machinery manufacturer THE REQUIREMENTS Automatic production of tracks for tractor crawler drives on construction vehicles, according to customer specifications and with an output of 25 parts / min.

THE SOLUTION The tracks are produced automatically on a PK 3500 crank forging press in five forging operations. The press works with a part feeder and an electronic transfer system for part handling.

Schuler developed the die holder and the complete forging process including operation sequence and material flow for each station. Commissioning and optimization of the press tools is done by Schulers tool specialists at the customers site.

Die space of PK 3500 with dies and transfer system arranged for part transport.

Detail views of the forging die for track production. Operation 3 "Finish forging".

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PROCESS AND DIE DEVELOPMENT

Systems for cold forging

Hydraulic cold extrusion presses Hydraulic ironing presses Hydraulic presses for manufacturing Compressed Natural Gas (CNG) cylinder tanks Horizontal multi-station presses for forging of wire Multi-station presses with link drive

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Systems for cold forging

Overview

HYDRAULIC COLD EXTRUSION PRESSES Tight parts tolerance High-precision workpieces Increased output and flexibility Large number of forging stations HYDRAULIC IRONING PRESSES No limits on component lengths High component quality Deep-drawing and ironing operation in one forging procedure

SYSTEMS FOR MANUFACTURING CNG GAS CYLINDER TANKS Low material costs for blanks Low weight Large container diameters are possible High surface quality HORIzONTAL MULTI-STATION PRESSES FOR FORGING OF WIRE Optimum ergonomic access to die space High level of user friendliness Very good visibility of the die space Ease of maintenance MULTI-STATION PRESSES WITH LINK DRIVE High output Long die life Highly complex part shapes Optional servo drive

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SYSTEMS FOR COLD FORGING Overview

Systems for cold forging

Hydraulic cold extrusion presses

MH series 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 advantages especially for long shaftshaped parts. 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. 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.

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

Hydraulic cold extrusion press.

Hydraulic cold extrusion presses SYSTEMS FOR COLD FORGING

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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).

OVERVIEW OF COLD EXTRUSION PRESS MODELS

Model Press force [kN] Max. slide stroke [mm] Number of stations MH 315 3,150 250 750 13 MH 500 5,000 250 750 13 MH 630 6,300 500 1,000 14 MH 800 8,000 500 1,000 14 MH 900 9,000 500 1,000 14 MH 1000 10,000 500 1,250 15

Model Press force [kN] Max. slide stroke [mm] Number of stations

MH 1250 12,500 700 1,250 15

MH 1600 16,000 700 1,250 15

MH 2000 20,000 900 1,250 15

MH 2500 25,000 900 1,250 16

MH 3150 31,500 900 1,250 16

MH 4000 40,000 900 1,250 16

Subject to technical modifications. Different tonnages are available upon request.

APPLICATIONS Hydraulic cold extrusion presses

Long-shaft components such as: Drive shafts Axle shafts Transmission shafts Truck axles

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SYSTEMS FOR COLD FORGING Hydraulic cold extrusion presses

CASE STUDY Systems for cold forging hydraulic cold extrusion presses

THE CUSTOMER Automotive supplier THE REQUIREMENT 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 fivestation 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
Die change arm for quick changeover. Hydraulic active grippers with patented damping system, clamping force is 10 kN.

Loading station.

Tri-Axis Compact Mono Beam Transfer.

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Bin tipper Vibration hopper Step feeder Sorting scale Loading station Tri-Axis Compact Mono Beam Transfer Safety device Finished part conveyor Finished part containers 9 Press Die change arm Control pendant panel

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Hydraulic cold extrusion presses SYSTEMS FOR COLD FORGING

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Systems for cold forging

Hydraulic ironing presses

MHS series 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

Very long components can be produced on hydraulic ironing presses.

Blanks and cups are processed on the same machine without any return stroke.

OVERVIEW OF HYDRAULIC IRONING PRESSES IN HORIzONTAL DESIGN

Model Press force [kN] Number of die chambers Model Press force [kN] Number of die chambers MHS 63 / 63 2 630 2 MHS 80 / 80 2 800 2 MHS 100 / 100 2 1,000 2 MHS 125 / 125 2 1,250 2 MHS 160 / 160 2 1,600 2 MHS 200 / 200 2 2,000 2 MHS 250 / 250 2 2,500 2 MHS 315 / 315 2 3,150 2

MHS 400 / 400 2 4,000 2

MHS 500 / 500 2 5,000 2

MHS 630 / 630 2 6,300 2

MHS 800 / 800 2 8,000 2

MHS 1000 / 1000 2 10,000 2

MHS 1250 / 1250 2 12,500 2

MHS 1600 / 1600 2 16,000 2

Subject to technical modifications. Different tonnages are available upon request.

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SYSTEMS FOR COLD FORGING Hydraulic ironing presses

MH series 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.
Extreme slide strokes require extreme press dimensions. Manipulators transferring the blank from the parts conveyor into the die.

OVERVIEW OF VERTICAL HYDRAULIC IRONING PRESSES

Model Press force [kN] Number of die chambers MH 250 2,500 1 MH 315 3,150 1 MH 400 4,000 1 MH 500 5,000 1 MH 630 6,300 1 MH 800 8,000 1 MH 1000 10,000 1 MH 1250 12,500 1 MH 1600 16,000 1

Subject to technical modifications. Different tonnages are available upon request.

APPLICATIONS Hydraulic ironing presses

Long, thin walled parts such as: CO2 cartridges Shock absorbers Hollow shafts

Hydraulic ironing presses SYSTEMS FOR COLD FORGING

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Systems for cold forging

Hydraulic presses for manufacturing CNG gas cylinder tanks

MH series COMPRESSED NATURAL GAS FOR A CLEANER FUTURE. Today, more and more vehicles are driven with alternative fuels. The travel distance of gas-fuelled 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.

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

Die space.

Line with three hydraulic presses. Press force: 19,000, 12,000 and 8,000 kN.

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SYSTEMS FOR COLD FORGING Hydraulic presses for manufacturing CNG gas cylinder tanks

CNG CONTAINERS: FROM INEXPENSIVE 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.

Line for manufacturing CNG gas cylinder tanks from blanks.

APPLICATIONS Hydraulic presses for manufacturing CNG gas cylinder tanks

CNG gas cylinder tanks

Hydraulic presses for manufacturing CNG gas cylinder tanks SYSTEMS FOR COLD FORGING

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Systems for cold forging

Horizontal multi-station presses for forging of wire

Typ FM 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. THE ADVANTAGES

With FormMaster multi-station presses, Schuler offers presses that meet these requirements. Designed in dialog with users, production and

maintenance specialists, toolmakers and designers, the FormMaster offers high productivity and maximum availability.

Optimum ergonomic access to die space High level of user friendliness Very good visibility of the die space Ease of maintenance Reliable servo transfer with transport parameters adjustable from the control panel Part transport monitoring Machine requires 30 % less floor space Integrated die cooling / lubrication system

Horizontal multi-station presses for forging of wire.

Easy to adjust ejector system.

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SYSTEMS FOR COLD FORGING Horizontal multi-station presses for forging of wire

OVERVIEW OF HORIzONTAL MULTI-STATION PRESSES FOR FORGING OF WIRE

Model Press force [kN] Forming stations Wire cut-off at 600 N / mm [ mm] Die diamter die side [ mm] Die diameter punch side [ mm] Cut-off length max. [mm] Weight [t] Production rate [ppm] FM 80 800 5 / 6 12 75 55 120 18 220 FM 100 1,000 5 / 6 14 90 75 125 25 180 FM 130 1,300 5 / 6 15 90 75 140 29 160 FM 200 2,000 5 / 6 21 95 85 160 42 140 FM 250 2,500 5 / 6 23 110 90 180 48 120 FM 350 3,500 5 / 6 25 130 110 195 55 100 FM 500 5,000 5 / 6 30 150 130 260 92 90 FM 630 6,300 5 / 6 36 175 145 290 125 70 FM 850 8,500 6 42 215 175 345 140 55 FM 1500 15,000 6 52 260 215 425 180 45

Subject to technical modifications. Different tonnages are available upon request.

APPLICATIONS Horizontal multi-station presses for forging of wire

Various parts from the fitting, joining, automotive industry, tools and hardware

Horizontal multi-station presses for forging of wire SYSTEMS FOR COLD FORGING

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Systems for cold forging

Multi-station presses with link drive

MML series EFFICIENCY, STEP BY STEP. Multi-station presses with link drive 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. 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 for kinematic motion of the slide that can be selected 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

Stroke

Conventional eccentric drive

Motion sequence with link drive

Multi-station press for cold forging transmission shafts. Press force: 16,000 kN, slide stroke: 800 mm.

The link drive system permits high output rates and production with reduced die wear.

Time

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SYSTEMS FOR COLD FORGING Multi-station presses with link drive

OVERVIEW OF MULTI-STATION PRESSES WITH LINK DRIVE

Model Press force [kN] Ram stroke [mm] Stroke rate [strokes / min] Bed surface [lr fb mm] MML 315 3,150 250 500 30 60 22 45 1,000 600 MML 400 4,000 250 500 30 60 22 45 1,000 600 MML 630 6,300 315 500 25 50 25 50 1,250 710 MML 800 8,000 315 500 25 55 22 45 1,250 710 MML 1000 10,000 400 630 25 50 18 38 1,500 1,000

Model Press force [kN] Ram stroke [mm] Stroke rate [strokes / min] Bed surface [lr fb mm]

MML 1200 12,000 400 630 25 50 18 38 1,500 1,000

MML 1600 16,000 630 800 18 40 16 36 1,800 1,000

MML 2000 20,000 630 800 18 40 16 36 1,800 1,000

MML 2500 25,000 630 800 18 36 16 32 2,200 1,000

MML 3150 31,500 630 800 18 36 16 32 2,200 1,000

Subject to technical modifications.

Link drive system for multi-station presses.

APPLICATIONS Multi-station presses with link drive

Parts for: Engines / transmissions Drive components Suspension components Fasteners Roller bearing elements

Multi-station presses with link drive SYSTEMS FOR COLD FORGING

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MSL series COMBINATION WITH SERVO DRIVE. Combining the link drive system with servo drive technology makes it possible to improve upon the advantages of the link drive concept. This results in highly flexible production systems with increased output rates.

THE ADVANTAGES WITH OPTIONAL SERVO DRIVE

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

CASE STUDY Systems for cold forging Multi-station presses with link drive

THE CUSTOMER Automotive supplier THE REQUIREMENT Supply a turnkey solution for economical series production of steering system components in the automotive industry. SYSTEM SOLUTION Schuler supplied a multi-station press with link drive: 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

Schuler supplied a multi-station, press with link drive, press force 8,000 kN.

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SYSTEMS FOR COLD FORGING Multi-station presses with link drive

Systems for warm forging

Multi-station presses with eccentric drive Multi-station presses with link drive

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SYSTEMS FOR WARM FORGING

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Systems for warm forging

Overview

MULTI-STATION PRESSES WITH ECCENTRIC DRIVE Large die space Wide press force range Very good output Long stroke lengths Long die lifes Short contact time

MULTI-STATION PRESSES WITH LINK DRIVE High output Large die space High component quality

Information about multi-station presses with link drive can be found starting on page 28

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SYSTEMS FOR WARM FORGING Overview

Systems for warm forging

Multi-station presses with eccentric drive

MME series SHORT CONTACT TIMES. Multi-station presses with eccentric drive 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. In order to make a fully automated production line, the flexible controls can incorporate a wide range of peripheral devices.

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

OVERVIEW OF MULTI-STATION PRESS MODELS WITH ECCENTRIC DRIVE

Model Press force [kN] MME 315 3,150 250 500 30 60 22 45 1,000 600 MME 400 4,000 250 500 30 60 22 45 1,000 600 MME 630 6,300 315 500 25 50 25 50 1,250 710 MME 800 8,000 315 500 25 55 22 45 1,250 710 MME 1000 10,000 400 630 25 50 18 38 1,500 1,000

Ram stroke [mm] Stroke rate [strokes / min] Bed surface [lr fb mm]

Model Press force [kN]

MME 1200 12,000 400 630 25 50 18 38 1,500 1,000

MME 1600 16,000 630 800 18 40 16 36 2,300 1,000 (1,750 1,000)

MME 2000 20,000 630 800 18 40 16 36 2,300 1,000 (1,750 1,000)

MME 2500 25,000 630 800 18 36 16 32 2,300 1,000 (1,750 1,000)

MME 3150 31,500 630 800 18 36 16 32 2,300 1,000 (1,750 1,000)

Ram stroke [mm] Stroke rate [strokes / min] Bed surface [lr fb mm]

Subject to technical modifications.

Multi-station presses with eccentric drive SYSTEMS FOR WARM FORGING

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The classic eccentric drive in its compact design offers a range of advantages, 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. Combination with multiple feeder and transfer devices is also possible. These advantages can also be used successfully in applications involving cold forging and precision forging.
NC-transfer and die space area.

Stroke

Eccentric sequence

Eccentric drive in compact design.

The eccentric drive provides economical high-volume production.

Time

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SYSTEMS FOR WARM FORGING Multi-station presses with eccentric drive

MSE series COMBINATION WITH SERVO DRIVE. Combining the eccentric drive system with servo drives makes it possible to extend the advantages of this drive concept. The result is a highly flexible production system with increased output rates.

THE ADVANTAGES WITH OPTIONAL SERVO DRIVE

Increased output rates Individually programmable ram speeds and motion sequences

Ability to adapt motion sequence to 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

Stroke

Conventional eccentric drive

Various slide kinematics are possible with optional servo drive.

Time

APPLICATIONS Multi-station presses with eccentric drive

Parts for: Engines / transmissions Drive components Suspension components Fasteners Roller bearing elements

Multi-station presses with eccentric drive SYSTEMS FOR WARM FORGING

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CASE STUDY Systems for warm forging Multi-station presses with eccentric drive

THE CUSTOMER Automotive supplier THE REQUIREMENT Deliver a fully automated line for warm forging production of driveline components SYSTEM SOLUTION Schuler delivered a multi-station press with eccentric drive: 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

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Bin tipper Vibration hopper Step feeder Scale with sorting device Lateral transport conveyor Pre-graphitizing station Graphite tank Induction heating Die lubrication tank Conveyor for colder part removal Container for colder parts Operating panel Protective device on the infeed side Transfer system Press Protective device on the exit end Die change arm Cooling section Finished parts container

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SYSTEMS FOR WARM FORGING Multi-station presses with eccentric drive

5 Systems for hot forging

Short-stroke hammers Counterblow hammers Screw presses Crank forging presses Multi-station presses with eccentric drive Open die forging systems in cooperation with PAHNKE Hydraulic forging presses Hydraulic presses for forging ring blanks Hydraulic presses for forging aluminum wheels 56 58 60 62 40 43 46 51

SYSTEMS FOR HOT FORGING

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Systems for hot forging

Overview

SHORT-STROKE HAMMERS Very high stroke rates Minimum pressure contact times Low operating costs COUNTERBLOW HAMMERS Extremely high impact energy and forging power (tonnage) High reliability and availability High stability of the overall structure SCREW PRESSES Wide range of parts High repeat accuracy High reliability CRANK FORGING PRESSES High production speed Fully automated parts handling High production accuracy MULTI-STATION PRESSES WITH ECCENTRIC DRIVE Long stroke lengths Large die space Precision forging

More information about multi-station presses with eccentric drive can be found on page 33

OPEN DIE FORGING SYSTEMS IN COOPERATION WITH PAHNKE High productivity Energy efficient drive techno ogy l Excellent uptime and availability

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SYSTEMS FOR HOT FORGING Overview

HYDRAULIC FORGING PRESSES More accurate pre-forging with high press forces, therefore reduced rolling work Weight savings due to greater accuracy High output HYDRAULIC PRESSES FOR FORGING RING BLANKS High forces for extremely large parts High flexibility / high output Proven press concepts HYDRAULIC PRESSES FOR FORGING ALUMINUM WHEELS Highest possible press forces in compact space Proven press concepts High precision and quality of forged wheels

Overview SYSTEMS FOR HOT FORGING

39

Systems for hot forging

Short-stroke hammers

KGH series MAXIMUM EFFICIENCY EVEN IN SMALL-TO-MEDIUM BATCH SIzES. Short-stroke hammers are used for many kinds of applications, and are particularly suitable for small-tomedium 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

ADDITIONAL EQUIPMENT

Automation Anvil bed heating Anti-vibration installation Acoustic insulation Customer-specific custom solutions

Short-stroke hammer with manual operation for small batch volumes.

Short-stroke hammers with solid U-frame.

40

SYSTEMS FOR HOT FORGING Short-stroke hammers

OVERVIEW OF SHORT-STROKE HAMMER MODELS

Model Working capacity [kJ] Impact frequency max. [per min] Slide stroke max. [mm] Slide depth [mm] Clearance between guides [mm] Total die height max. [mm] Total weight [t] KGH 1.6 16 122 635 470 520 320 24 KGH 2 20 120 665 510 570 345 30 KGH 2.5 25 113 685 550 608 360 36 KGH 3.15 31.5 100 755 595 664 420 46 KGH 4 40 98 790 640 717 455 60 KGH 5 50 98 775 695 766 435 75 KGH 6.3 63 95 805 750 831 465 96 KGH 8 80 92 835 830 890 495 121 KGH 10 100 83 885 890 960 540 143 KGH 12.5 125 75 1,160 1,020 1,060 720 195 KGH 16 160 70 1,190 1,050 1,150 750 235

Subject to technical modifications.

1 2 3 4 5 6 1 2 3 4 5 6 Drive head Piston rod Slide Upper die U-frame Lower die

Drive head of a KGH 2.5.

APPLICATIONS Short-stroke hammers

Chassis components Flanges Connecting rods Turbine blades Hand tools

Short-stroke hammers SYSTEMS FOR HOT FORGING

41

CASE STUDY Short-stroke hammers

THE 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 shortstroke 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.

Part handling and forging performed by two robots.

Automatic hammer line with shortstroke hammer KGH 4.0B

1 2 3 4 5 6

Furnace Part feeding conveyor belt Short-stroke hammer KGH 4 Robot Robot 'Pass' parts conveyor belt

Process flow direction

42

SYSTEMS FOR HOT FORGING Short-stroke hammers

Systems for 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

ADDITIONAL EQUIPMENT

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

Die change systems Tup heating systems Ejector systems Spraying systems

Hydraulic counterblow hammers

Counterblow hammers with hydraulic drives are particularly well suited to the medium tonnage range. This means there is no need for a complicated compressed air installation.
1 2 3 4 5 6 7 8 9 10 Drive head Piston rod Upper tup Upper die Upright Tup support Lower die Lower tup Hydraulic tup coupling Buffer

HG series

1 2 3

OVERVIEW OF HYDRAULIC COUNTERBLOW HAMMER MODELS

Model Working capacity [kJ] Impact frequency max. [per min] Slide stroke max. [mm] Slide depth [mm] Clearance between guides [mm] Total die height max. [mm] Total weight [t] HG 16 160 50 960 1,450 1,100 315 133 HG 20 200 50 910 1,600 1,200 355 161 HG 25 250 50 840 1,750 1,300 355 203 HG 31.5 315 45 840 1,800 1,350 400 255 HG 40 400 45 745 2,150 1,500 450 322

5 6 7

9 10

Subject to technical modifications.

Counterblow hammers SYSTEMS FOR HOT FORGING

43

DG series

4 5 6

Pneumatic counterblow hammers

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.
1 2 3 4 5 6 7 8 9

DG 140

Top part of machine Upper tup 8 Upper die Upright 9 Tup support Lower die Lower tup Hydraulic slide coupling Buffer

OVERVIEW OF PNEUMATIC COUNTERBLOW HAMMER MODELS

Model Working capacity [kJ] Impact frequency max. [per min] Slide stroke max. [mm] Slide depth [mm] Clearance between guides [mm] Total die height max. [mm] Total weight [t] DG 16 160 50 745 1,450 1,100 315 120 DG 20 200 45 840 1,600 1,200 355 145 DG 25 250 45 840 1,750 1,300 355 180 DG 31.5 315 40 910 1,800 1,350 400 210 DG 40 400 40 960 2,150 1,500 450 285 DG 50 500 36 970 2,400 1,500 450 355 DG 63 630 36 1,020 2,700 1,600 450 433 DG 80 800 32 1,035 3,000 1,600 500 650 DG 100 1,000 28 1,100 3,400 1,700 550 850 DG 125 1,250 25 1,150 3,600 1,900 550 1,050 DG 140 1,400 25 1,225 3,700 2,000 600 1,200

Subject to technical modifications.

APPLICATIONS Counterblow hammers

Crankshafts Turbine blades Driveline and chassis components for cars and trucks Flanges and disks

44

SYSTEMS FOR HOT FORGING Counterblow hammers

CASE STUDY Systems for hot forging counterblow hammers

THE 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 80 h 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.
Production of crankshafts on a counterblow hammer with a rated capacity of 800 kJ.

1 2 3 4 5 6 7

Manipulator Storage area Furnace Descaling Drop machine Counterblow hammer Trimming and calibrating press

Semi-automated forging line with counterblow hammer and trimming /calibrating press.

Counterblow hammers SYSTEMS FOR HOT FORGING

45

Systems for hot forging

Screw presses

SCREW PRESSES ARE VIRTUOSOS. 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.

From 1963 onward, once reliable three-phase synchronous motors with rapid permitted switching frequencies were available; the door was open 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 Frequency Drive

1 Cooling motor 2 Main motor stator with motor housing 3 Rotor shrunk onto flywheel 4 Screw 5 Crown 6 Thrust bearing 7 Tie bar

1 2 3 4 5 6 7

ADDITIONAL EQUIPMENT

Ejector in the bed and slide Die change systems Customer-specific solutions

Drive system of a screw press.

APPLICATIONS Screw presses

orgings for the automotive F industry and commercial vehicles such as crankshafts, axles, connecting rods or transverse links Fittings Flanges Hand tools, cutlery urgical instruments as well S as turbine components

46

SYSTEMS FOR HOT FORGING Screw presses

PA / PAR series PA / PAR SERIES. 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. In particular, small components made from non-ferrous metals and requiring high precision can be forged efficiently on type PA and PAR screw presses.

OVERVIEW OF SERIES PA / PAR SCREW PRESS MODELS

Model Screw diameter [mm] Continuously permitted press [kN] Die-to-die blow force [kN]. Gross working capacity PA [kJ] Gross working capacity PAR [kJ] Stroke rate max. [min-1] Distance bed slide max. [mm] Bed surface [mm] Total weight [t] PA 125 125 2,500 3,200 4.5 33 620 460 500 7 PA 140 140 3,200 4,000 6.5 32 670 500 550 8 PA 160 160 4,000 5,000 10 29 730 540 570 11 PA 180 180 5,000 6,300 14 24 24 790 580 610 14 PA 200 200 6,400 8,000 19 32.5 23 850 620 650 19 PA 225 225 8,000 10,000 27 45 21 930 680 710 25 PA 265 265 11,000 14,000 42 72 20 1,050 750 x 780 39 PA 300 300 14,000 18,000 60 105 19 1,150 800 x 850 55 PA 325 325 16,000 20,000 75 130 18 1,250 850 x 900 72 PA 360 360 21,000 26,000 100 170 17 1,350 900 x 1,000 97

Subject to technical modifications.

1 2 3 4 5

Drive Frame Ram Upper die Lower die

2 3 4 5

A type PA spindle press can also be used for producing components from non-ferrous metals.

Screw presses SYSTEMS FOR HOT FORGING

47

PSM / PSH series PSM / PSH SERIES. The medium PSM / PSH series are produced as a two-piece casting held together by four tie rods. In the PSM series, the tie rods absorb surplus energy once a defined forging force has been reached, 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 2 3 4 Drive Crown Screw Ram 5 6 7 8 8 Frame Upper die Die change arm (option) Lower die 3 4 5 6 7 2 1

OVERVIEW OF SERIES PSM / PSH SCREW PRESS MODELS

Model Screw diameter [mm] Continuously permitted press [kN] Die-to-die blow force [kN]. Gross working capacity PSM [kJ] Gross working capacity PSH [kJ] Stroke rate max. [min ]
-1

PSM 265 265 11,000 14,000 65 90 20 780 750 860 40

PSM 300 300 14,000 18,000 100 140 19 860 820 870 55

PSM 325 325 16,000 20,000 120 170 18 920 860 920 70

PSM 360 360 21,000 26,000 160 225 18 1,000 930 1,000 85

PSM 400 400 26,000 32,000 210 300 17 1,080

PSM 450 450 32,000 40,000 315 420 16 1,200

PSM 500 500 40,000 50,000 400 560 16 1,300

PSM 560 560 50,000 63,000 500 700 15 1,450

PSM 630 630 64,000 80,000 700 1000 14 1,460

Distance bed slide max. [mm] Bed surface [mm] Total weight [t]

1,000 1,080 1,100 1,180 1,200 1,280 1,320 1,400 1,600 1,990 115 150 200 300 430

Subject to technical modifications.

48

SYSTEMS FOR HOT FORGING Screw presses

PzS series
1

PzS SERIES. 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.
3 1 2 3 4 5 6 7 8 Flywheel Motor Crown Ram Upper die Upright Lower die Bed 2

5 6 7

Machining a screw at the Weingarten facility.

OVERVIEW OF SERIES PzS SCREW PRESS MODELS

Model Screw diameter [mm] Continuously permitted press [kN] Die-to-die blow force [kN]. Gross working capacity [kJ] Stroke rate max. [min-1] Distance bed slide max. [mm] Bed surface [mm] Total weight [t] PzS 710 710 80,000 100,000 1,150 / 2,200 10 1,200 1,600 2,000 490 PzS 800 800 100,000 126,000 1,650 / 3,000 9 1,700 2,050 2,000 790 PzS 900 900 128,000 160,000 2,250 / 4,000 9 1,800 2,100 2,200 1,150 PzS 1000 1,000 160,000 200,000 3,150 / 6,000 8 2,000 2,400 3,000 1,650 PzS 1120 1,120 200,000 250,000 4,000 / 6,800 8 2,000 2,400 3,000 1,850 PzS 1200 1,200 230,000 290,000 5,000 / 8,500 7 2,200 2,600 3,000 2,150 PzS 1325 1,325 280,000 360,000 7,000 / 10,000 4 2,300 3,100 3,700 2,600

Subject to technical modifications.

Screw presses SYSTEMS FOR HOT FORGING

49

CASE STUDY Systems for hot forging screw presses

THE 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 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 of the PZS-series in operation.

7 1 2 3 4 5 6 7 8 9 Rotary hearth furnace Descaling Reducer roll Screw press PZS 900f Robot / manipulator Trimming and calibrating press Twister Calibrating press Cooling section

50

SYSTEMS FOR HOT FORGING Screw presses

Systems for hot forging

Crank forging presses

PK

series

SpeedForge crank forging presses

SPEEDFORGE. Mechanical high-performance crank forging 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 nonferrous materials.
1

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

5 6 1 2 3 4 5 6 7 8 9 10 11 Drive Crown Crankshaft Upright Ram Ram ejector Die holder Transfer Die Bed ejector Bed 7 9 8

10 11

Crank forging presses SYSTEMS FOR HOT FORGING

51

Crank forging presses with DualDrive

DUALDRIVE OPENS NEW HORIzONS. The newly developed DualDrive concept for crank forging 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. 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.
1 2 3 4

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 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.

THE ADVANTAGES

Reduced contact time Reduced die wear More time for die cooling and part transport

1 2 3 4

DualDrive Crank shaft Flywheel drive Flywheel

Stroke [mm] 300 250 DualDrive 200 150 100 50 0 0

Conventional eccentric drive Contact time 0.5 1.0 Time [s]

Reduced pressure contact time with DualDrive.

52

SYSTEMS FOR HOT FORGING Crank forging presses

OVERVIEW OF CRANK FORGING PRESS MODELS

Model Nominal force [kN] Stroke rate continuous [1 / min]. Working capacity single [kJ] Ram stroke [mm] Ram adjustment [mm] Shut height [mm] Bed depth [mm] Bed width [mm] PK 1250 12,500 70 180 300 15 850 1,050 1,280 PK 2000 20,000 65 320 300 20 1,100 1,500 1,640 PK 3150 31,500 60 550 400 25 1,500 1,390 2,170 PK 4000 40,000 60 750 425 20 1,600 1,450 2,200 PK 5000 50,000 50 1,000 450 20 1,700 1,500 2,250 PK 6300 63,000 40 1,300 450 20 1,700 1,600 2,300

Subject to technical modifications.

Main drive of crank forging press PK 3150.

Planetary gearbox between flywheel and crank shaft.

APPLICATIONS Crank forging presses

Chassis components Flanges Drive components Bearing races Gear blanks

Crank forging presses SYSTEMS FOR HOT FORGING

53

CASE STUDY Systems for hot forging crank forging presses

THE CUSTOMER Automotive components industry THE REQUIREMENTS Fully automated production system for flanges with high output. THE SOLUTION Schuler supplied a complete production line comprised of part feed, induction heating system, PK 3150 crank forging press with DualDrive,

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 Dual Drive.

A forging glows in the die

1 2 3 4 5 6

Part feeder Induction furnace Loader Crank forging press with automation equipment Conveyor belt Cooling section

Process flow direction

54

SYSTEMS FOR HOT FORGING Crank forging presses

PRESS CONTROL SYSTEM SCHULER FORGE CONTROL SYSTEM (FCS) The Schuler-FCS control system represents the latest development in control systems for screw presses and forging hammers. It has been developed especially for forging machines, and combines the latest features for high flexibility and high accuracy in controlling machine parameters. Depending on the machine and application, the standard functions include a wide range of stroke control options or impact program specifications, energy and part thickness measurement, control loops for energy and TDC position, as well as documentation functions for die and production data.

THE ADVANTAGES

Ease of operation because of uniform graphical user interface with touch screen 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 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

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

Simple operation with graphical user interface.

Uniform touch screen user interface.

Crank forging presses SYSTEMS FOR HOT FORGING

55

Systems for hot forging

Open die forging systems in cooperation with PAHNKE

MHFT/ MHFU series 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. 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.

THE ADVANTAGES
high productivity energy efficient drive technology excellent uptime and availability

Open die forging press in push down design.

Open die forging press in pull down design with manipulator.

OVERVIEW OF OPEN DIE FORGING SYSTEMS MHFT / MHFU MODELS

Modell Press force in MN Ram stroke in mm Bed surface in mm MHF8 8.0 MHF10 10.0 MHF12.5 12.5 MHF16 16.0 MHF20 20.0 MHF30 30.0 MHF45 45.0 MHF60 60.0 MHF80 80.0 MHF100 100.0

1,000 2,200 1,000 2,200 1,200 2,500 1,350 2,850 1,600 3,400 1,800 4,000 2,400 5,000 3,000 6,000 3,500 7,000 4,000 8,000 1,400 750 1,600 850 1,800 1,000 2,000 1,100 2,300 1,200 2,500 1,400 3,500 1,550 4.000 1,800 4,500 2,000 5,000 2,200
Subject to technical modifications.

56

SYSTEMS FOR HOT FORGING Open die forging systems

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.

For open die forging, Schuler has built on its capabilities by forming a strategic partnership with Pahnke, a long-time and experienced name in the forging business. 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.

APPLICATIONS Open die forging systems

Slabs Diffrent kinds of shafts Sleeves Rings Special forgings

Open die forging systems SYSTEMS FOR HOT FORGING

57

Systems for hot forging

Hydraulic forging presses

MH series FORGING AND ROLLING RAILWAY WHEELS. Railway wheels are manufactured in three forging stages before they are processed further with machining (metal cutting). First, the heated billet is pressed into a disk-shaped 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.

Hydraulic press for forging railway wheels.

Wheel rolling mill for railway wheels

THE ADVANTAGES
High press forces achieve more accurate pre-forging, reducing rolling work

Weight saving due to greater accuracy High output

APPLICATIONS Hydraulic forging presses

Railway wheels for cars Railway wheels for engines

58

SYSTEMS FOR HOT FORGING Hydraulic forging presses

EXAMPLES OF HYDRAULIC FORGING PRESSES. The working sequences before and after the actual forging are frequently performed on hydraulic presses. On hydraulic pre-form presses, preforms 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 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 dis-

tances of 4 m. Examples include hot forging presses, piercing presses and presses for partial forging of fittings and thick-walled pipes.

OVERVIEW OF HYDRAULIC FORGING PRESSES

Model Press force [kN] Number of stations Model Press force [kN] Number of stations MH 500 5,000 13 MH 4000 40,000 16 MH 800 8,000 13 MH 5000 50,000 16 MH 1000 10,000 14 MH 6000 60,000 16 MH 1600 16,000 14 MH 7000 70,000 17 MH 2000 20,000 15 MH 2500 25,000 15 MH 8000 80,000 17 MH 3000 30,000 15 MH 9000 90,000 17 MH 3500 35,000 15 MH 10000 100,000 17

Subject to technical modifications. Different tonnages are available upon request.

APPLICATIONS Hydraulic forging presses

Fittings for pipelines Thick-walled pipes Rail ends Large flanges and brake disks (pre-forming) Crank shafts (calibrating) Axle parts (calibrating)
Hydraulic forging presses SYSTEMS FOR HOT FORGING

59

Systems for hot forging

Hydraulic presses for forging ring blanks

MH series WHETHER BIG OR SMALL, ROUNDNESS AND PRECISION ARE THE MAIN CRITERIA. The first forging operation when manufacturing seamless rings is forging ring blanks. 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
Ring blank progression.

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

Hydraulic press of the MH-series.

Coordinated die processes, in-house die and process expertise

Forging ring blanks with hydraulic press technology.

60

SYSTEMS FOR HOT FORGING Hydraulic presses for forging ring blanks

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 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 and 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.

FEM simulation of symmetrical piercing on both sides.

OVERVIEW OF HYDRAULIC PRESS MODELS FOR MANUFACTURING RING BLANKS

Model Press force [kN] Number of stations Model Press force [kN] Number of stations MH 800 8,000 13 MH 5000 50,000 13 MH 1000 10,000 13 MH 6000 60,000 13 MH 1600 16,000 14 MH 7000 70,000 14 MH 2000 20,000 14 MH 8000 80,000 14 MH 2500 25,000 14 MH 9000 90,000 14 MH 3000 30,000 14 MH 10000 100,000 14 MH 3500 35,000 14 MH 12000 120,000 14 MH 4000 40,000 14 MH 14000 140,000 14

Subject to technical modifications. Different tonnages are available upon request.

APPLICATIONS Hydraulic presses for forging ring blanks

Seamless rings as the precursor for: Bearing shells Crown gears Flanges Blade carriers for jet engines Various highly stressed structural elements
Hydraulic presses for forging ring blanks SYSTEMS FOR HOT FORGING

61

Systems for hot forging

Hydraulic presses for forging aluminum wheels

MH series FORGING ALLOY WHEELS. Weight savings achieved in the driveline are increasingly 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 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

Hydraulic press for forging aluminum wheels.

Complete lines from a single source

OVERVIEW OF HYDRAULIC PRESS MODELS FOR FORGING ALUMINUM WHEELS

Model Press force [kN] Number of stations Model Press force [kN] Number of stations MH 500 5,000 1 MH 4000 40,000 1 MH 800 8,000 1 MH 5000 50,000 1 MH 1000 10,000 1 MH 6000 60,000 1 MH 1600 16,000 1 MH 7000 70,000 1 MH 2000 20,000 1 MH 8000 80,000 1 MH 2500 25,000 1 MH 3000 30,000 1 MH 9000 90,000 1 MH 3500 35,000 1 MH 10000 100,000 1

Subject to technical modifications. Different tonnages are available upon request.

62

SYSTEMS FOR HOT FORGING Hydraulic presses for forging aluminum wheels

ADAPTED FORGING PROCESSES. 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.

Aluminum wheel progression.

APPLICATIONS Hydraulic presses for forging aluminum wheels

Aluminum wheels

Hydraulic presses for forging aluminum wheels SYSTEMS FOR HOT FORGING

63

CASE STUDY Systems for hot forging hydraulic presses for forging aluminum wheels

THE 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 lubricant conditioning device and linear manipulator with rotary head.

Both oil-based lubricants and waterbased 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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SYSTEMS FOR HOT FORGING Hydraulic presses for forging aluminum wheels

Global service

GLOBAL SERVICE

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Global service

SERVICE COMPLETE PERFORMANCE Technical services can play an important role in achieving success in the customers plant. We have more than 900 service staff at work, day-in and day-out, all over the world. Services available include procurement and project planning through the production phase of the lines. The core building blocks to serve our customers include technical service for ensuring line availability, boosting performance by line modernization and extensive training courses for optimizing line utilization.

TECHNICAL SERVICE

Complete service Maintenance and servicing Preventative maintenance Safety check on line for accident prevention regulations Spare parts and repairs Energy checks Machine relocation Tele-service

PERFORMANCE ENHANCEMENT

Modernization Machine optimization Die and process technology Pre-owned machines

TRAINING

Schuler Academy Production support

Complete technical services to ensure productivity and efficiency.

On-site employee training by qualified trainers and start-up personnel.

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GLOBAL SERVICE

Optimizing existing forging systems can extend service life and improve productivity. Our experience and knowledge of the latest technology and processes are continuously channeled into efforts for improved performance.

SERVICE FROM A SINGLE SOURCE

Peltzer & Ehlers

Modernization of existing lines can be an economical alternative.

Schuler has more than 900 service staff at work, day-in and day-out, all over the world.

GLOBAL SERVICE

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ADDRESSES Global partners for forging technology

forging@schulergroup.com www.schulergroup.com /forging

GERMANY Schuler AG Bahnhofstr. 41 73033 Gppingen Phone + 49 7161 66 -0 Fax + 49 7161 66 -233 Schuler Pressen GmbH Bahnhofstr. 41 73033 Gppingen Phone + 49 7161 66 -307 Fax + 49 7161 66 -729 Schuler Pressen GmbH Werk Weingarten Schussenstr. 11 88250 Weingarten Phone + 49 751 401-2211 Fax + 49 751 401-952211 Schuler Pressen GmbH Werk Erfurt Schwerbornerstr. 1 99086 Erfurt Phone + 49 361 700 Fax + 49 361 706001 Schuler Pressen GmbH Servicecenter Remscheid Industriegebiet Bergisch-Born Am Weidenbroich 1a 42897 Remscheid Phone + 49 2191 9519-90 Fax + 49 2191 9519-981 Schuler SMG GmbH & Co. KG Louis-Schuler-Str. 1 68753 Waghusel Phone + 49 7254 988-226 Fax + 49 7254 988-490

Schuler SMG GmbH & Co. KG Servicecenter Esslingen Rntgenstr. 16 18 73730 Esslingen Phone + 49 711 939-80 Fax + 49 711 939-5279 Grbener Pressensysteme GmbH & Co. KG Wetzlarer Str. 1 57250 Netphen Phone + 49 2737 962-0 Fax + 49 2737 962-100 Schuler Automation GmbH & Co. KG Werk Hedorf Louis-Schuler-Str. 1 91093 Hedorf Phone + 49 9135 715 -0 Fax + 49 9135 715 -159 Schuler Automation GmbH & Co. KG Werk Gemmingen Louis-Schuler-Str. 9 75050 Gemmingen Phone + 49 7267 809 -0 Fax + 49 7267 809 -182 Schuler Cartec GmbH & Co. KG Werk Gppingen Bahnhofstr. 41 73033 Gppingen Phone + 49 7161 66 -0 Fax + 49 7161 66 - 622 Schuler Cartec GmbH & Co. KG Werk Weingarten Gartenstr. 54 88250 Weingarten Phone + 49 751 401- 03 Fax + 49 751 401-2931
Schuler SMG, Waghusel Schuler Pressen, Remscheid Schuler Pressen, Erfurt Schuler Pressen, Weingarten Schuler Group Headquarters, Gppingen

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ADDRESSES

Schuler Cartec Engineering GmbH & Co. KG Gartenstr. 54 88250 Weingarten Phone + 49 751 401-04 Fax + 49 751 401-2931 Schuler Gu GmbH & Co. KG
Schuler Group Headquarters, Gppingen

GREAT BRITAIN Schuler Presses UK Ltd. Brineton Street Quayside Drive Walsall, West Midlands WS29LA Great Britain Phone +44 1922 619-100 Fax +44 1922 619-101 ITALY SW Italia S.r.l. Via Erasmo da Rotterdam 4 10134 Turin Italy Phone +39 011 31-66511 Fax +39 011 31-99237 SWITzERLAND

Bahnhofstr. 41 73033 Gppingen Phone + 49 7161 66 -890 Fax + 49 7161 66 - 616 Vgtle Service GmbH & Co. KG Friedhofstr. 115 73054 Eislingen Phone + 49 7161 9973 - 0 Fax + 49 7161 9973 -13 UmformCenter Erfurt GmbH Schwerborner Str. 1 99086 Erfurt Phone + 49 361 7066 - 50 Fax + 49 361 7066 - 51 TRAVIS Handelsgesellschaft mbH Schussenstr. 11

Schuler SMG, Esslingen

Beutler Nova AG Hofmatt 2 6142 Gettnau Switzerland Phone +41 41 9727575 Fax +41 41 9727576 SLOVAKIA Schuler Slovakia Services, s.r.o. . tra 101841 Dubnica nad Vhom Slovakia Phone +421 42 286 1341 Fax +421 42 281 2002

Schuler Automation, Gemmingen

88250 Weingarten Phone + 49 751 401- 2762 Fax + 49 751 401- 2842 FRANCE Schuler France S.A. 17. rue Schertz, BP 26 67023 Strasbourg Cedex 1 France Phone +33 388 657080 Fax +33 388 403490

Schuler Automation, Hedorf

Grbener Pressensysteme, Netphen

ADDRESSES

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ADDRESSES Global partners for forging technology

SPAIN Schuler Ibrica S.A.U. Edificio SCV Forum Planta 2a, Puerta 4a Ctra. Sant Cugat-Rubi, Km 01, no 40 50 08190 Sant Cugat del Valls (Barcelona) Spain Phone +34 93 54423-00 Fax +34 93 54423-01 RUSSIA Schuler AG Moskauer Reprsentanz Prospekt Wernadskowo 103 Korpus 2 119526 Moskau Russia Phone +7 495 4332309 Fax +7 495 4342363 CzECH REPUBLIC Mller Weingarten esk Republika s.r.o. ivotice u Novho Jina . p. 118 74272 Mokov Czech Republic Phone +420 556 779 -911 Fax +420 556 779 -904 USA Schuler Incorporated 7145 Commerce Boulevard Canton, Michigan 48187 USA Phone +1 734 2077200 Fax +1 734 2077222

BCN Technical Services, Inc. 1004 East State Street Hastings, Michigan 49058 USA Phone +1 269 9483300 Fax +1 269 9483310 MEXICO Mller Weingarten de Mxico, S.A. de C.V. Lateral Arco Norte Km.25 #4 Col. Parque Industrial Ocotln San Francisco Ocotln Coronango, Puebla, Mxico C.P. 72680 Mexico Phone +52 222 4310019 Fax +52 222 4310018
Beutler Nova, Gettnau, Switzerland Schuler Cartec, Weingarten

Mller Weingarten de Mxico, S.A. de C.V. Saltillo Calle Automotriz # 3065 esq. Metalmecnica Parque Industrial Saltillo-Ramos Ramos Arizpe, Coahuila. C.P. 25900 Mexiko Phone +52 844 4885947
Mller Weingarten, Morkov, Czech Republic

BRAzIL Prensas Schuler S.A. Av. Fagundes de Oliveira, 1515 09950-904 Diadema, So Paulo Brazil Phone +55 11 4075-8444 Fax +55 11 4079-2766
Schuler France, Strasbourg, France

Schuler Iberica, Barcelona, Spain

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ADDRESSES

CHINA Shanghai Schuler Presses Co. Ltd. No. 8, Lane 750 Luo Chuan Zhong Road Shanghai 200 072 PR China Phone +86 21 56650081
Schuler Incorporated, Canton, MI, USA

INDIA Schuler India Pvt. Ltd. 401 403 Keshava, Bandra-Kurla Complex Bandra (East) 400 051 Mumbai India Phone + 91 22 66800300 Fax + 91 22 66800399

Fax +86 21 66529060 Tianjin SMG Presses Co., Ltd. Yinfeng Huanyuan A 1004 Youyi Bei Road 65 Hexi District Tianjin 300204 PR China Phone +86 22 83280895 Fax +86 22 83280540

Schuler India Private Limited Unit 204, 2nd Floor Suyash Classic 75 + 75/2 Baner Road Baner, Pune - 411045 India Phone + 91 94 440-79263

BCN, Hastings, MI, USA

Schuler Sales & Service Co., Ltd. No. 8, Lane 750 Luo Chuan Zhong Road Shanghai 200 072 PR China Phone +86 21 56650081 Fax +86 21 66529060
Prensas Schuler, So Paulo, Brazil

Mller Weingarten (Dalian) Forming Technologies CO., Ltd. No. 1 Weingarten Road Dalianwan Ganjingzi District Dalian 116113 PR China Phone +86 411 87124002 Fax +86 411 87609916

Shanghai Schuler Presses, Shanghai, China

Schuler AG Beijing Representative Office Room 1012 Talent International Building No. 80, Guangqumennei Dajie Chongwen District Beijing 100062 PR China Phone +86 10 51696769

Mller Weingarten Forming Technologies, Dalian, China

Fax +86 10 51696768

ADDRESSES

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Schuler PreSSen GMBh Bahnhofstr. 41 | 73033 Gppingen | Germany Phone +49 7161 66-307 | Fax +49 7161 66-729

Schuler PreSSen GMBh Werk Weingarten | Schussenstr. 11 88250 Weingarten | Germany Phone +49 751 401-2211 | Fax +49 751 401-952211

Schuler SMG GMBh & co. KG Louis-Schuler-Str. 1 | 68753 Waghusel | Germany Phone +49 7254 988-226 | Fax +49 7254 988-490

forging@schulergroup.com | www.schulergroup.com/forging

400E-092011-WSP-2000 Copyright by Schuler