Metal Forming Presses Brochure

Australia Siempelkamp Pty Ltd.BrazilSiempelkamp do Brasil Ltda.CanadaSiempelkamp Canada Inc.ChinaSiempelkamp (Wuxi) Machinery Manufacturing Ltd., BeijingFranceSiempelkamp France SarlItalySiempelkamp S.r.I.RussiaSiempelkamp MoscowSingaporeSiempelkamp Pte Ltd.SpainSiempelkamp Barcelona USASiempelkamp L.P.* Minority shareholdingwww.siempelkamp.comMetalforming PressesSiempelkamp Maschinen- und Anlagenbau GmbH & Co.KG Siempelkampstr. 75 47803 Krefeld GermanyPhone: +49 (0) 2151/ 92-30 Fax: +49 (0) 2151/ 92-53-60 www.siempelkamp.comRepresentativesMachinery and PlantsW. Strothmann GmbH Sicoplan N.V.Zweigniederlassung Maschinen- und Anlagenbau Büttner Gesellschaft für Trocknungs- und Umwelttechnik mbHCMC S.r.I.Maschinen- und Anlagenbau EngineeringIndustrieplanungHandling SystemeSiempelkamp (Wuxi) Machinery Manufacturing Ltd.Machines & Handling*ATR Industrie-Elektronik GmbH & Co. KGSchermesser S.A.Handling Systeme*Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KGSiempelkamp Handling Systeme GmbHEnergy SystemsSiempelkamp Energy Systems GmbHSheet Metal Forming Presses2 3Side Member DrawPressSingle-Frame DesignFor blanking and drawing of side members for trucksThese presses can be equipped with producthandling systems and equipment for quicktool changeSide member draw press, 50 MNSide members45 MN deep draw pressRear axle housingsHeat ExchangerPlate Press With: sheet handling systemsequipment for quick tool changeFor the manufacture of heat exchanger plates and large sheet metal componentsmade of stainless and alloy steels, titaniumalloys, etc.Heat exchanger plate press line, 150 MNTypical productsRubber Pad PressWith: table loading systems orcomputer-controlled pallet round-about systemSolid rubber pad presses (Guerin method) forultra-high specific forming pressures, suitablefor the production of high definition sheetmetal components for the aerospace industryand similar applicationsRubber pad press, 260 MNAxle Housing DrawPressHydroforming Presses Pipe Forming Presses4 5For the manufacture of shaped parts from pipes and tubes with the internal high-pressureCrimping PressHydroformingHydroforming press, 50 MN 110 MN crimping pressTypical tool for hydroformingA crimped 50 mm plateWith: program controlintegrated robots, handling equipmenttool changing systemsSiempelkamp high pressure intensifierWith: automatic parallelism control independent of the pipe lengthelectronic stroke controlintegrated transport systemsdevices for quick tool changeTry-out pipe forming press, 40 MN 720 MN O-forming pressPipe Forming PressLinesFor the production of large diameter pipes by the ‘C’-, ‘U’- and ‘O’-methodO-Forming PressThe largest press of this type in the worldcomes from SiempelkampNew designDue to the higher pressing force it is now possible to also form highest strength materialAssemblyAfter the planning, manufacture and finishing, the assembly is the finalstep in delivering a reliable, comprehensive solution. The Siempelkampteams are there at the client’s, ensuring that this last step is carried outwith the same expertise and efficiency.CommissioningThe successful commissioning gives our clients the security that fromnow on they will be able to count on the reliability of Siempelkamptechnology to help them supply their markets with the goods theyproduce. For us, the commissioning is an important link in the chain ofour production processes – and the insurance that we have deliveredan optimal product to our clients. As such, our commissioning is notjust an important part of our production chain, but also a valuablemilestone in our relationship to our clients.for our metal forming presses. Our analyses with various FEM systems(e.g. ANSYS and MARC/Mentat) support us in meeting these demandsby calculating the entire model of the presses being built. The advan-tages: the real stresses that occur during operation are shown moreprecisely, making the design of the individual parts more reliable.Once the stresses are defined, sub-models can be used to analyzeindividual parts and their interconnections. The stress analysis is carried out according to recognized German and international rulesand standards (e.g. FKM Guidelines, IIW recommendations, AD bulletin, VDI2230).Heavy-weight casts from our own foundryWhen it comes to the casting of ultra-heavy special and high-precision parts we are constantly setting new benchmarks – e.g. withour current cast of a 260 t moving crosshead. Using the drawings ofour design engineers, our company foundry, with its high level ofexpertise in manually produced casts, plays a decisive role in the success of our products. Here as well, our range of services is trulycomprehensive and offers our clients significant added value.Construction tailored to your needsIn engineering, trustworthytraditions are a valuablething. These traditions con-stantly benefit from better,more modern and more precise means of productionthat open up new perspectives in machinemanufacturing.Siempelkamp uses thesepotentials to create client-oriented solutions. The electronic drawing board of CAD programsmakes it possible to turn three-dimensional volume models into multi-dimensional drawings and animated visualizations – providing theperspectives necessary for developing client-specific solutionsFEM calculations create transparencyA long lifespan with very little wear and tear, low-level maintenanceand optimal usability: those are the clearly formulated demands setMetal Forming Presses: Complete Solutions6 7Assembling of the press frames The press table is installed The upper beam goes into the pressReady for commissioning3D animation of a crimping pressValues calculated by FEMComplete solutions: design, casting, machining, assembly andcommissioning from a single sourceAs one of the leading global providers of metal forming machinery, we set international standards. Weoffer our clients a combination of machine construction and process engineering know-how that is unique.This combination of skills enables us to provide our clients with comprehensive solutions that cover theentire spectrum from the design and construction of a machine to its final commissioning.Forging Plate forming Pipe forming Sheet metal forming HydroformingCasting of a 260 t upper beamWelded construction of an upper beamPortal milling machine machining the upper beamFinishingOur quality standards are carried right through the entire productionchain and include the finishing phase: the chip removing process forpress tables and moving crossheads on one of the largest portal millingmachines in Europe is carried out with the highest level of quality andprecision. The same is true for our hydraulics testing area: here thehydraulics can be tested even before the machine is put together.Whether frame, crosshead or pressing table, cylinder and hydraulics:everything is built in Krefeld, and our focus is always on precision,including the precision of the software programs we develop.Hydraulic room High rack stacker with fully automatic shelf stackerHydraulic components in the workshop9Metal Forming Presses: Complete Solutions8Here as well, we have specialists that design and produce systemsspecifically for your needs.There is also a separate team specifically for the switchgear cabinet.The electric components are parameterized in advance and then testedtogether with the hydraulics. Electronic components are produced bysuch renowned manufacturers as Siemens, Allen Bradley, etc.All operations are united in one control system and are accessiblethrough a unified operator interface, enabling the machine operator to quickly learn how to use the new controls and ensuring a safehandling of the press.Siempelkamp metal forming presses have a very high degree of automation.For example, we offer “computer-aided forging” for open-die forgingpresses. When tool numbers are entered, the machine calls up ‘passschedules’ and then forges the required piece automatically.Process control technology is also made by Siempelkamp.With the Prod IQ system, Siempelkamp offers an integrated processcontrol technology that registers all of the relevant parameters fromthe completely networked parts of the machine. This information isregistered in layer, commission and stand still production logs, whichthen form the basis for a more economical production. The goal hereis to attain a high degree of process stability and a maximum machineutilization rate.Handling and storageThrough two specialized subsidiaries, Siempelkamp is also able tooffer comprehensive solutions for product handling as part of thepressing process.Siempelkamp Handling Systems are the specialists for automation inthe area of roller conveyors and suction vehicles for separation andstacking.With its linear robots, Strothmann stands for flexibility and productivity.A high level of dynamism while handling large weights and the optimaluse of space are the characteristics that define products such as blankloaders, blank coating systems, centering stations and orienting stations.Siempelkamp Handling Systems can also offer its customers theadvantages of having a storage system integrated into the productionenvironment.The basis for the system is a steel high-bay storage system with fullyautomated storage and retrieval. The efficient storage administrationHydraulicsIn addition to mechanics, Siempelkamp’s process know-how alsoincludes the important area of hydraulics.Our dedicated hydraulics department is made up of around 80 employees who design and manufacture the highly specializedhydraulic power units required specifically for pressing.Quality control is carried out in our own testing facilities where thefunctionality of our hydraulics is tested so that only absolutely flawless units are delivered to the construction site.In addition, we always try to ensure the highest possible degree ofprefabrication, for example for such things as the hydraulic piping.Parts that are not produced by Siempelkamp are always sourced fromrenowned manufacturers such as Rexroth, Oil Gear Towler, Hydac, etc.These manufacturers have service centers around the world and canprovide you with spare parts no matter where you are located. Everythingwe do aims at achieving short commissioning and ramp-up times.Electric unitsThe third column of our comprehensive solutions for the manufactureof metal forming presses is Siempelkamp’s own electric controlsystems and our process control engineering.Computer-aided forging Complete production lineSwitch cabinet manufacturing Line feeder in motionForging Plate forming Pipe forming Sheet metal forming Hydroformingsystem makes every product available at any time. The advantages are the excellent use of space, safe and material-friendly transport and an optimal tie-in to the production system which results in greater flexibility and a higher degree of availability.Complete production linesWith its all-encompassing know-how, Siempelkamp is able to designand deliver entire pressing units and production lines. We develop,manufacture and commission machining concepts for your entire production process.Our focus is always on the greatest possible customer benefit andhow to produce that benefit economically.ServiceAll Siempelkamp systems offered on the market come complete withlife-time service. So, despite their legendary reliability, you are coveredin case the unexpected does happen: Our internet service helps toquickly deal with the initial fault analysis. Service points around theglobe can offer fast and efficient help with spare parts and manpowerto get the repair done. That gives the operators of our machines thesecurity of having a strong partner at their side who has been buildingand looking after presses for 125 years.11Plate Forming Presses Forging Presses10For hot and cold forming of half shells,spherical segments of various shapes for largecontainer and tank constructionWith: special bending toolworkpiece manipulatorsshifting tabletool changing devicesPlate Bending PressFor heavy plates, slabs, bars, tubes, shafts, etc.lateral cylinder shifting arrangementworkpiece transportmeasuring devicesworkpiece manipulatorselectronic control of straightening strokeStraightening PressPlate bending and dishing press, 100 MNStraightening press for heavy plates 39 MN open-die forging pressForming of a half shellOpen-Die ForgingPressWith: integrated manipulatorsdie clamping and turning devicedie cross shifting unitdie magazinetable shiftingIn two-column frame design, push-down orpull-down version; for the forging of bars,rings, discs, preforms, pierced blanks, etc.Forging process supported by:· computer-aided forging program· state-of-the-art visualizationEfficiency of production increased by:· shortest die-changing cycles· highest possible forging speed and frequency due to a shock-free smoothhydraulic control system:· 120 strokes/min. while planishing· 40 strokes/min. while coggingOpen-die forging press, 40/45 MN with manipulatorView into the working area12 13Forging PressesStroke-independent press for economic manufacturing of conventional die forgings or precision forgings by upsetting, extruding,calibrating, coining, trimming, etc.With: great forming energy per working strokefull pressing force at any ram positionvariable stroke limitationshortest hot contact timeoptimal ram guidingClutch-ControlledScrew Press16 MN original clutch-controlled screw press Typical parts1. High-performance clutch2. Flywheel3. Thrust bearing4. Return cylinder5. Lubrication oil6. Press frame7. Screw8. Ram9. Ram bolster plate10. Ram-side ejector11. Bed plate12. Bed-side ejectorWith: four-point parallelism controlexactly adjustable forming speedtool heating systemsconnecting equipment for vacuumand inert gas systems manipulatorsWheel forging line, 80/50/30 MN including die-changing devicesA forged rim for trucksBottle forging line consisting of upset and pierce press, 22.5 MN; ironing press, 3.4 MNFor high-tech forged parts with extreme contour accuracyClosed-Die ForgingPress Gas bottlesFor the production of cylindrical parts, gasbottles, pressure vessels, pierced blanks, etc.by the upsetting, piercing and ironing methodWith: program controlfully automatic workpiece handling equipmentquick tool changing systemstool lubricating and cooling systems14 15Forging PressesFor high-tech forged parts withextreme contour accuracyWith: program controlfully automatic workpiece handling equipment quick tool changing systemstool lubricating and cooling systemsParts of nickel-based alloys400 MN closed-die forging pressClosed-DieForging Pressfor AircraftPartsWire-Wound DesignAreas of applicationThe wire-winding technology is mainly used on metal components inpress construction and in pressure vessel manufacturing.These areas of mechanical engineering require the control of very highinternal pressures with resulting high press forces. In addition, thegoal is to achieve an optimized design by minimizing the dimensionsand the weight of the body.A solution to this problem is the use of the wire-winding technologyas shown in the example of a hydroforming press.Under compression the fatigue strength of cast iron is much higherthan under tension, up to twice as much. The combination of castingdesign and wire-winding creates a harmonic stress field, avoidingstress concentrations while reducing the weight of the machine.Pre-stressed wire-wound frames manufactured by the Siempelkamp foundry have been successfully used in various metal forming applications.Wire-wound press frame. Press force 200,000 kN Wire-wound hydroforming press,computer simulationPress frame for a hydroforming press. Press force 100,000 kNa Weight of casting: 86 tb Weight of wire: 8 tc Closing cylinderd Retraction cylindere Toolf Multiple blank holder positionsg Cassette driveh BlankSmith diagram for ductile cast iron GJS-400Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG Siempelkampstrasse 75 47803 Krefeld Germany Tel.: +49 (0) 21 51/92-30 Fax: +49 (0) 21 51/92-56 04 www.siempelkamp.comAll rights reserved. No part/parts of this publication may be reproduced, transmitted, edited or published in any form or by any means, electronic or mechanical, without the written permission from Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG © Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KGSales companies/RepresentativesAustralia Siempelkamp Pty Ltd.Brazil Siempelkamp do Brasil Ltda.ChinaSiempelkamp (Wuxi) Machinery ManufacturingLtd.,BeijingFrance Siempelkamp France SarlIndia Siempelkamp India Pvt. Ltd. Russia Siempelkamp MoscowSingapore Siempelkamp Pte Ltd.SpainSiempelkamp BarcelonaTurkeySiempelkamp IstanbulUSA Siempelkamp L.P.Siempelkamp Handling Systeme GmbHSicoplan N.V.Büttner Gesellschaft für Trocknungs- und Umwelttechnik mbHCMC S.r.I.Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KGEngineeringHandling SystemeSiempelkamp Logistics & Service GmbHATR Industrie-Elektronik GmbHSiempelkamp Energy Systems GmbHW. Strothmann GmbH Machines & HandlingSiempelkamp (Wuxi) Machinery Manufacturing Co. Ltd., China Hombak Maschinen- und Anlagenbau GmbHSiempelkamp CZ s. r. o.