Forming and process experience from the operation of a 3,000 ton Flexform deep draw press

Transcription

1 Forming and process experience from the operation of a 3,000 ton Flexform deep draw press Document no SE Revision 1 Page 1(3) White paper Siemens Industrial Turbomachinery AB. Sture Olsson and Ingemar Nygren, Quintus Technologies, Västerås, Sweden, May 2016 The Principle of Flexform Example of products: About Siemens Turbomachinery AB The Siemens modern production facilities in Trollhättan, Sweden encompass 8,600 m 2 with a recent expansion of 3,700 m 2 shop floor. The production is flow oriented and run via the lean principles. The manufacturing can be divided into three main core competencies: SGT600 Combustor Diameter: 1000 mm 2 mm Hastelloy X» Welding (TIG, MIG/MAG, plasma, resistance and laser)» Laser processing (flat bed and fve axis cutting and welding)» Pressing/Forming Through long term agreements with sub suppliers we can offer; heat treatment in vacuum, thermal barrier coatings, material laboratory services and machining capacity up to a diameter of 2,500 mm. SGT600 Combustor Diameter: 1000 mm 2 mm Hastelloy X 1

2 The 3,000 ton Flexform deep draw press Original installation: 1965 Latest large upgrade in 2011 Stroke speed: Average set-up: Fluid form tables: seconds 2 hours #1: 445 mm inner ø. 2,000 bar #2: 618 mm inner ø. 1,000 bar #3: 775 mm inner ø. 600 bar Siemens offers excenter pressing, hydraulic pressing, expander pressing, press brakes roll-forming, and deep drawing in a 3,000-ton Quintus press (formerly ASEA). A comparison of different flexible forming methods. 2

3 Tooling examples Deep drawing tool for roller bearing cage In this example a deep drawing tool is used to pre-form a roller bearing cage. After the pre-form the product is 1,100 mm in diameter, depth 200 mm in 8 mm thickness. Material thinning of 0.2 mm is accepted at worst point. Expansion tool Another example is an expansion tool that is used to pre-form a cone. In the next step a cavity tool is used to finish form the product. Final product being 180 mm in diameter, height 230 mm, material 1 mm Inconel. Negative draft is possible due to the split tool design. Main advantages with deep drawing» Bigger depth possible vs conventional press» Suitable for complex shapes, even undercuts/negative draft is possible» Suitable for tougher material» Good tolerances» Half the tooling cost (only the female tool required)» Avoid heat treatment that is needed for same shape in a conventional» Less thinning and thus less stress to material vs conventional press» Possible to use sharpening piece for special features e.g. sharp radius» No scratches on the blanks, thanks to the smooth rubber/oil tool half 3

4 Flamehead, SGT500 gas turbine, 2 mm Hastelloy X 1. Tooling set-up. Tooling firmly positioned in the table, but the table is movable. 4. Laser cut blank with steering hole (ø 50 mm) in the middle. 2. Tricolan rubber with hardness 50 shore. 5. Laser cut blank greased with ricin oil on the downward facing surface put on the tooling. 3. Tooling and fluid form unit (red) in starting position. Tooling retracted inside the raised table. 6. Press fully set-up with tricolan rubber ready to start forming. 4

5 Flamehead, SGT500 gas turbine, 2 mm Hastelloy X 7. Fluid form unit fully covers the tooling. The holding pressure is created, and both the table and the fluid form unit are pushed downwards. Operation time is seconds. 8. Press opened, and the pressed part is ready to be replaced with a new blank. 9. Finished component ready for the next operation, in this case 3D laser cutting. 5

6 Conclusions The Quintus press is our oldest and most reliable partner in the workshop. Suitable for small series prototyping as well as meeting our serial production demands. Stephen Shotton, Production Engineering Manager, Siemens Industrial Turbomachinery AB The press at Siemens is the great grandfather to Quintus s new generation of deep-draw presses. The new deep-draw press is a true multi-purpose press, with no less than four forming methods in one machine: cavity, block, deep-draw and expansion! Quintus Technologies unparalleled quality, and press life-length gives you a reliable partner for decades. Download the Deep-Draw Hydroforming Presses data sheet from our web site: quintustechnologies.com/datasheet A modern Quintus 8,000 ton Deep-draw press with two Ø 800 mm forming tables. Typical products with data Material: Brass 1.2 mm Diameter: 150 mm Height: 200 mm First step: Deep drawing with protective outer shell Second step: Expansion tool Material: Alu 1.2 mm Length: 400 mm Height: 300 mm First step: Deep drawing with protective outer shell Heat treatment Second step: Expansion tool Material: Hast X 3.2 mm Length: 350 mm Height: 150 mm First step: Cavity tool Heat treatment Second step: Cavity tool incl. plungings (10 mm deep) 6