World largest Radial Forging Machine starts production at CARPENTER TECHNOLOGY in USA Jahrestagung STAHL 6.November 2014, Düsseldorf Dr. Albrecht Holl Dr. Paul-Josef Nieschwitz Dr. Frederik Knauf
Contents 1. Customer 2. Machine 3. Transport and Supply 4. Opening Ceremony 5. First Results 2 June 2014
CARPENTER Works in Alabama, USA melting shop forging shop heat treatment shipping department volumen of investion 518.000.000 USD area 500.000 foot² ( 46.450 m²) productionstart 2014 employees ca. 200 3
CARPENTER Products for Aerospace-Industry Source: Internet CARPENTER TECHNOLOGY Quelle: Carpenter Technology 4
Contents 1. Customer 2. Machine 3. Transport and Supply 4. Opening Ceremony 5. First Results 5 June 2014
SMX 1100/22 MN at time the biggest hydraulic forging- machine in the world Customer Carpenter Technology, USA Year of order 2011 Force, max. Diameter, max. Input weight, max. Final diameter, min Forging frequence Planishing frequence 22 MN 1100 mm round 10000 kg 100 mm 70 140 Strokes / Minute 180 Strokes / Minute Forged materials Productivity steels, corrosion resistant steels, nickel-based- and superalloys and titanium ca. 50.000 t/a 6
weight : approx. 160.000 kg 7 SMX 1100/22 MN: Press Frame
SMX 1100/22 MN: Press-Cylinder 8 weight: approx. 37.000 kg
SMX 1100/22 MN: The SMX Family last SMX 1100 (2014): max. opening Ø 1.100 mm max. length 15.000 mm max. force 22 MN first SMX 180 (1992): Ø 180 mm 6.000 mm 2,75 MN 9 2m
SMX 1100/22 MN: Axial Movement of Manipulator weight : approx. 180.000 kg rolls instead of sliding plates 10
SMX 1100/22MN: Conventional Rotary-Drive with worm gear, limit at 8.000 kg ingot-weight 11
SMX 1100/22 MN: New Concept for Rotary-Drive new rotary-drive with brake disk up to 10.000 kg weight brake caliper for pulling brake caliper for pushing 12
SMX 1100/22MN: New Rotary-Drive New rotation-drive with brake disc (customers wish) up to 10.000 kg ingot-weight 13
SMX 1100/22 MN: New Rotary-Drive realised 14
SMX 1100/22 MN: Complete Manipulator Tong 15
SMX 1100/22 MN: Dimensions Manipulator Tongs 16
SMX 1100/22 MN: Assembly of Manipulators weight : ca. 180.000 kg 17
Contents 1. Customer 2. Machine 3. Transport and Supply 4. Opening Ceremony 5. First Results 18 June 2014
SMX 1100/22 MN: Transport of the Frame 19
SMX 1100/22 MN: Transport of the Manipulators 20
SMX 1100/22 MN: Fundament 21
SMX 1100/22 MN: Erection Frame and Cylinder-Assembly 22
SMX 1100/22 MN: Hydraulic Station Main Components number of pumps (HD: 350 bar) 12 (ND: 175 bar) 12 number of motors (400 kw) 12 23
SMX 1100/22 MN: Manipulator 24
SMX 1100/22 MN: Tool-Changing Device 26
Contents 1. Customer 2. Machine 3. Transport and Supply 4. Opening Ceremony 5. First Results 27 June 2014
SMX 1100/22 MN: Opening Ceremony 28
SMX 1100/22 MN: Opening Ceremony opening ceremony: January 27th 2014 acceptance test SMX: June 06 th 2014 29
Contents 1. Customer 2. Machine 3. Transport and Supply 4. Opening Ceremony 5. First Results 30 June 2014
SMX 1100/22 MN: Forging first Ingot effective date contract: 11. November 2011 forging 1. ingot: 31. December 2013 31
SMX 1100/22 MN: Some Forgings, stepped Shaft 32
SMX 1100/22 MN: Some Forgings, Round 33
SMX 1100/22 MN: Some Forgings, Round Corner Square 34
SMX 1100/22 MN: Some Forgings, Flat 35
SMX 1100/22 MN: Some Forgings, loading ESR-Round 36
SMX 1100/22 MN: Some Forgings, first Pass ESR-Round 37
SMX 1100/22 MN: Some Forgings, RCS unloading 38
SMX 1100/22 MN: Customers Statement Jim Seitz, Programmdirektor bei Carpenter: Mit der Schmiedemaschine von SMS Meer können wir Schmiedeprodukte sehr wirtschaftlich produzieren. Die große Kapazität und die enorme Presskraft der Maschine geben uns die Flexibilität, auf veränderte Nachfragebedingungen schnell zu reagieren 40
Thank you very much! Muchas Gracias! Muito obrigado! 非常感谢! Vielen Dank! Merci beaucoup! Много благодаря!!شكرا جزيال Большое спасибо! Tack så mycket! Tante grazie! Paljon kiitoksia! Heel erg bedankt! 정말감사합니다! どうもありがとう! Þakka þér fyrir! 41 Mange tak! Σας ευχαριστώ πολύ! Děkuji moc! Tusen takk! Hvala vam puno!