upgrade no32 2014 e - protesa · umbrella organization for eleven national forg-ing organizations....
TRANSCRIPT
up gradeNewsletter for customers, employees and partners volume 16, issue no. 32, September 2014
Know-how
News
Higher efficiency through electric upsettingThe demand for higher and higher efficien-
cy in production brings a classic forming
process, the electric upsetting, a renais-
sance: Due to extended requirements,
LASCO has completely re-engineered the
well-proven technology and offers lines
that highly convince in many fields of ap-
plication.
Hirschvogel relies on LASCO pre-forming unitThe well-known German automotive
supplier Hirschvogel ordered a LASCO
forging roll type RCW 560 So for its
production site in Pinghu, China.
Mubea calibrates with direct drive technologyThe new hydraulic servo direct drive from
LASCO is now used by Mubea, special-
ist for heavy-duty spring components for
vehicles, too. The automotive supplier
calibrates disk springs with a new LASCO
multi-purpose press VPE 400 in its plant
in Daaden (Germany).
LASCO UMFORMTECHNIKWERKZEUGMASCHINENFABRIK
Editorial
2
Trends + Markets
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Friedrich HerdanPartner and Chairman of the Board Langenstein & Schemann GmbH
Impressed by innovative strength Hanover Fair: State Minister Aigner visits LASCO
Bavarian Minister of Economic Affairs Ilse Aigner was impressed with the innovative strength of the mechanical engineering company during her visit to LASCO at the Hanover Fair.
The Minister got a personal impression of
the international competitiveness of Bava-
rian companies during her tour of the most
important industrial fair world-wide. At the
joint exhibition stand of the Industrieverband
Massivumformung e. V. (IMU) she was infor-
med about LASCO’s contribution to trends
and new develoments in the fields of material
and resource efficiency.
LASCO was one of 30 other IMU member
companies on an exhibition space of more
than 1000 m2. The key issue of “lightweight
forging” of the joint IMU exhibition picked up
the thread of the manifold research activities
of the association in this field.
We are looking at the growing international tensions caused by the political developments in the eastern neighbourhood of the EU full of concern and are sharing the hope with our business associates in Russia and the Ukraine that solutions will be found through diplomatic channels that will bring about acceptable reconciliation of the legitimate interests of all par-ties involved. This requires direct communication based on mutual respect.
We do not take it upon ourselves to judge decisions and deeds which are in the responsibility of politics. However, in the light of the 150 years of our company his-tory and international experience, it seems admissible to emphasize one idea:
The highest dynamics in increas-ing wealth and benefits has always been achieved in times of inter-national cooperation and never in times of confrontation.
Throughout the times of global political changes of the 19th and 20th century LASCO has estab-lished and expanded international business relationships and has always been a reliable partner for our customers. We want to and will continue this way.
YoursFriedrich Herdan
Maintaining respect
Bavarian State Minister of Economic Affairs and Media, Energy and Technology and Deputy Minister-President of Bavaria Ilse Aigner (3rd from left) is getting information about LASCO from Sales Director Dr.-Ing. Stefan Erxleben (3rd from right) and Dr. Theodor Tutmann, Director of the Industrieverband Massivumformung e. V. (German Association for Solid Forming) (2nd from right) at the exhibition stand.
LASCO symposium for experts in Bratislava46 representatives of forming companies
from Slovakia, Czechia and Austria accepted
LASCO’s invitation to take part in a one-day
specialist symposium in Bratislava (Slovakia).
Its focus was on optimisation potential in
processes and technologies. Professor Bohuslav
Masek from the West Bohemian University in
Pilsen presented “New concepts and outlooks
on forging parts of the future”, Adis Huskic from
Leibniz University, Hanover, presented “Ex-
perimental and numerical studies of integrated
thermal treatment of forged steel components
using the forging heat”. LASCO experts Rainer
Scheler and Jochen Günnel gave information
on new and further developments from LASCO
such as the hydraulic servo direct drive or the
orbital forming press, the hydraulic horizontal
forging machine and stretching line AR-D as
well as on the forging and cross wedge roll with
direct drive.
21st IFC: Meeting point of the forging worldWith 750 delegates from 30 countries the 21st
International Forging Congress (IFC) in Berlin
(29 June – 1 July) advanced to the position of
meeting point for key members of the global
forging industry. The invitation for this event
was extended by EUROFORGE, the European
umbrella organization for eleven national forg-
ing organizations. The congress focussed on
high-calibre technical lectures on technology
and mega trends of the industry.
LASCO supported the event as ambassador
sponsor and took the unique opportunity to talk
to customers and prospective buyers from all
over the world at the accompanying exhibi-
tion. Following the congress 290 participants
accepted the offer to visit 41 leading forming
companies in seven European countries. A
large number of the host companies are among
LASCO’s customers and allowed access to their
production sites.
3
News
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Due to its sustained success
with LASCO technology the US
American Moline Forge pur-
chased another double-acting
hammer.Recently representatives of the enterprise in
Moline/Illinois put the HO-U 315 optimised
for their individual applications to the acid
test before they released it for shipment. The
obligatory machine acceptance of the form-
ing unit was a performance test attended by
experts, as Moline Forge is already absolutely
familiar with LASCO technology: At Moline
Forge hydraulic double-acting die-forging
hammers types HO-U 250, HO-U 500 and
hammers of the KH series from LASCO have
been in permanent use for decades. The US
forge produces forgings with approx. up to 40
kg used for rail traffic, mechanical engineering
and agriculture.
Impressed by innovative strength
Hirschvogel orders automated forging roll
Vehicle parts made of aluminium for ChinaIn the future the Hirschvogel
group in Pinghu/China will also
be using an automated forging
roll from LASCO for the manufac-
ture of vehicle parts made from
aluminium for Chinese customers.
The well-known German automotive supplier
is having a forging roll RCW 560 So with auto-
mation tailor-made and equipped with set-up
device and replacement rollers for its Chinese
production site near Shanghai (established in
2005).
The forging roll is designed for pre-forming
forging parts made from aluminium or alu-
minium alloys. Pre-forms for chassis parts
Customer acceptance of the HO-U 315 for Moline Forge (from right): Alexander Zeitler (head of LASCO spare part department), Jeffrey Bolton (service engineer LES/USA). Bernd Schubert and Holger Welsch (LASCO service technicians) with Dino Adamson (maintenance manager Moline Forge) and Jochen Günnel (deputy sales director LASCO).
Mubea calibrates more efficiently now The global Mubea group, too, has been using
the big efficiency advantage of the hydrau-
lic servo direct drive since recently. At the
production site in Daaden (Germany) a multi-
purpose press VPE 400 with servo direct drive
has been used since recently by the specialist
for heavy-duty spring components and related
products for calibrating disk springs. With
the line the characteristic curve of the spring
disk is set by a calculated calibrating process.
The trace of the force–displacement curve
is monitored and the calibrating process is
controlled correspondingly. Springs with outer
diameters of up to 1,000 mm and a material
thickness of up to 40 mm can be calibrated
at a maximum calibrating force of 4,000 kN.
The owner-managed family business Mubea
(main production site Muhr und Bender KG,
Attendorn/Germany) sees itself as global part-
ner to the automotive industry and lightweight
construction specialist for heavy-duty spring
components. With its lightweight construction
technologies, new materials and processing
methods Mubea substantially contributes to
the construction of lighter vehicles with in-
novative solutions.
from aluminium (rolling temperatures of up
to 560°C) with a max. weight of 9 kg will be
produced from raw material of a maximum
diameter of 115 mm and a length of 300 mm.
The line has been equipped with a tempe-
rature control system and a tool lubrication
system for the rolling of aluminium materials.
The forging roll will be integrated into a
forging line for which LASCO is supplying the
complete automation and control technology.
The Hirschvogel Automotive Group (with its
headquarters in Denklingen, Germany) is one
of the biggest automotive suppliers opera-
ting in solid forming of steel and aluminium
world-wide.
US forge purchased another double-acting hammer
LASCO electro-upsetters EV and EH
Reliable process and quality by:
� constant and monitored heating tem-
perature due to thyristor-controlled and
steplessly adjustable heating current,
� monitored upsetting speed,
� contact electrodes and guide jaws with
parallel and synchronized gripping at
constant height,
� monitoring and prevention of buckling.
Centric upsetting
A renowned German manufacturer of large
valves recently placed an order with LASCO
for three horizontal electro-upsetters type EH
315 (transformer capacity 315 kVA).
The units have undergone the customer
acceptance test and have been shipped
meanwhile. The standard design of one of
the units was complemented additionally by
a special device for upsetting a collar (centric
upsetting) for a system that rotates the valve
between the working cycles to reduce wear.
Sequence of operations: Basically “centric
upsetting” corresponds to “free upsetting
at the bar end”. The difference is that the
forged valve cooled down to room tempera-
ture is contacted by two pairs of electrodes
with different potential below the valve disk.
The valve disk is supported by a fixed stop,
and a feed at the bar end gathers volume in
a controlled way between the two pairs of
electrodes. The heating current merely flows
between the pairs of electrodes, the valve
disk and the shaft remain cold.
The once widespread electro-upsetting for
gathering volume on bar material made of
different metallic materials and alloys has
recently been experiencing a come-back
for special applications. With immediate
operational readiness (without a long start-up
process) upsetting can be carried out at the
bar end or any other part of the bar. Volume
gathered in free upsetting can be handled
in a further forming process without being
heated intermediately. Die upsets that are
produced in other competing forming pro-
cesses are usually too cold for further forging.
Furthermore the electric upsetting process is
not restricted to specific cross sections and
mostly round material is used.
Additional properties and advantages:
� Only the section to be upset is heated.
� No waste of heating energy and material.
The shaft which will not be deformed
stays cold.
� Low ohmic and inductive (eddy current)
losses.
� Very efficient energy consumption de-
manding 0.35 – 0.40 kWh/kg of heated
material due to the optimum design of
the high current circuit.
� No or drastically reduced scale formation.
� No environmental pollution by radiant
heat, smoke or other emissions.
� Good grain flow and wrinkle-free surface.
� Constant heating temperature.
Know-how
4 up grade LASCO 32/14
Energy-efficient and economicalElectro-upsetters in vertical and horizontal design now with extended process
Picture 1: Free upsetting
Possible processes and shapes of volume gathering
Picture 2: Form upsetting
Picture 3: Conical and spherical upsetting
Horizontal standard machine with clamping feed
LASCO electro-upsetters EV and EH
There are possible uses in energy generation
and the aviation industry that go beyond the
well-known and well-proven applications of
electric upsetting.
Volume required for the root and cover of
turbine blades made from high-alloy materials
can be gathered by free upsetting as well.
Centric upsetting is also suited for the mid-
spans of longer turbine blades.
Author: Franz Suttan
Further fields of application of the process
Know-how
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Energy-efficient and economicalElectro-upsetters in vertical and horizontal design now with extended process
Examples of applications of electro-upsetting
Fields of application of centric upsetting
Valves for combustion engines Tie rod end for steering
Rear axle shaft with spline end Drive shaft or torsion bar
Large valve collar
Aviation turbine
blade
Steam turbine blade
Picture of the machine for free, form and centric upsetting
Die forging
Billet (bar end)
Upset length Upsetting Trimming Piercing
Production of tie rod ends
Internal
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10 years with LASCOLars Ehrlicher 01.12.2013Wolfgang Foerster 01.05.2014Thierry Lebailly 17.05.2014Gerhard Schoder 01.06.2014
25 yaers with LASCOUlrike Rusert 01.03.2014Andrea Hamm 01.07.2014
Spotlights
High-precision boring mill: A new
boring mill type „SPIRIT T” of the
Italian manufacturer FTP has been
in operation at LASCO
since September
2013. The new
production
centre
offers a
number
of advantages
that lead to a reduction
of the machining time of parts. After
some months’ practical experience in
three-shift operation on five days/week
the expectations pinned to this invest-
ment have been met. According to
LASCO machine operators the „Spirit”
is a very solid machine with good
cutting data (feed, rotational speed),
it is convincing by its good machine
concept and specially suited for deep-
hole boring because of its high coolant
performance.
New facility: LASCO Beijing has
opened a new facility in Changchun to
be able to intensify its business activi-
ties in China and above all to shorten
the distances to customers. Li Bing
has been appointed Sales Director
Forging North China and Branch Man-
ager. Changchun City is the capital of
Jilin province and with its more than
seven million inhabitants the second
largest city in the northeast of the
People’s Republic of China. Because
of the numerous automotive compa-
nies located there it is also nicknamed
„China’s Detroit”.
„Dr.-Kapp-Vorbildpreis” for Florian Brehm
Exemplary commitment for public welfare
Franz Brosch (left), Director of the employers’ association bayme vbm Upper Franconia (Germany), and Martin Kapp, Managing Partner of the KAPP Group (right) are congratulating Florian Brehm on his award.
Florian Brehm, third year me-chatronics apprentice at LASCO, has been awarded the „Dr.-Kapp-Vorbildpreis”.
The award was named after its donor, Dr.
Bernhard Kapp, and founder of the KAPP
Group, an internationally active mechanical
engineering company from Coburg (Germany).
It honours unselfish commitment of young
people for public welfare. Florian Brehm has
been devoting a large part of his free time to
the volunteer fire brigade in Rödental (Germa-
ny), where he passed an intensive training in
fire fighting. Now he is responsible for training
junior fire fighters himself.
Brehm received the award together with
another 61 young people from companies in
the metal and electrical industry in Upper
Franconia who had been recommended by
their employers. The „Dr.-Kapp-Vorbildpreis”
includes prize money of EUR€10,000 and has
been awarded for the 10th time.
Vocational training finished successfullyFive young men successfully finished their apprenticeship at LASCO by passing their final exams at the Chamber of Commerce and Industry at Coburg (Germany). After the ceremony of handing over the diplomas Gernot Losert (left), Managing Director Administration/Production and the training supervisors Björn Bühling and Georg Pfeuffer (2nd and 1st form right) congratulated the cutting machine operators Richard Kouassi and Danny Streng (2nd and 3rd from left) as well as the industrial mechanic David Schubert (4th from left). Not in the picture: Robert Neumann (electronics technician for operating tech-nology) and Theodor Weinert (mechatronics technician).
Boring mill FTP Spirit T
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Internal
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Metalform ChinaBeijing, China
16. – 19.09.2014
SENAFORPorto Alegre, Brazil08. – 10.10.2014
EuroBLECHHanover, Germany21. – 25.10.2014
5th Asia Forge MeetingKaohsiung, Taiwan03. – 06.11.2014
Fairs + dates
up grade Volume 16, issue no. 32 – September 2014 Publisher: LASCO Umformtechnik GmbH Hahnweg 139 - 96450 Coburg Senior Editor: Dr.-Ing. Stefan Erxleben Photos: LASCO Umformtechnik, VDL Weweler, IHK zu Coburg, Georg Weber.
EU project „Leonardo da Vinci“
24 apprentices from the sectors metal technology, wood technology and electrical engineering were handed over the EU certificate „europass Mobilität” (europass mobility) after three-week internships in other European countries. Among them were Edy Hamuyela (industrial mechanic 2nd year of apprentice-ship) and Marius Kinhirt (3rd year of apprenticeship).
The aim of the EU project “Leon-
ardo da Vinci” LASCO has been
involved in for years is to im-
prove mobility, cooperation and
division of labour of the econo-
mies in the European Union.
LASCO has been taking part in the project
since its launch in the Coburg area in coo-
peration with the vocational schools and the
Chamber of Commerce and Industry by e. g.
the exchange of apprentices for internships
in other European countries. Recently the
Swedish apprentices Simon Goja and Frederik
Wafs from SKF in Gothenburg (Sweden) as
well as Anthony Deboo and Juha De Praetere
from the Belgian “Vrij Technisch Instituut” in
Waregem did internships of several weeks at
LASCO.
In return the LASCO apprentices Marius
Kinhirt and Edy Hamuela (both industrial
mechanics) could do an internship in Sweden
respectively in Austria.
After his three-week internship at SKF in
Gothenburg, Kinhirt said he would highly
Exchange of young people
Second round of „School physics meets mechanical engineering practice”The project „School physics meets mechanical engineering practice” intended to help secondary school students in Coburg to choose a professional career is being continued. At LASCO young people were now able to try out the contents of their physics class in the working life of a mechanical engineering company. The picture shows the guests together with their teachers StD Scherbel (2nd from right), OStR Geißler (4th from right), Deputy Sales Director Günnel (left), Managing Director Administration/Production Losert (2nd from left), the Head of Electrics/Electronics Stengel (4th from left) and graduate physicist Taubmann (Design Department forming/special machines – 7th from right).
Marius Kinhirt (right) with colleagues from other training companies from Coburg at the SKF museum in Gothenburg.
recommend this exchange of trainees to
everybody. According to him it was a good
experience of life to have to integrate oneself
in other countries, cultures and working me-
thods and to use one’s knowledge of foreign
languages. It showed to him that the specialist
knowledge acquired during his vocational trai-
ning so far could also be applied abroad. On
the other hand he was very impressed by the
working method of the Swedish enterprise that
reflected a strict commitment to sustainabi-
lity and environmental responsibility. Kinhirt
passed his internship together with three col-
leagues from other companies from Coburg.
He said he had experienced a very hearty and
open welcome.
up grade LASCO 32/14
In practice
up grade: Mr. Aalderink, your enterprise is the first company to use an automatic roller gap adjustment. What is its benefit for Weweler?
Dick G. Aalderink: We don’t want to waste any material in the pre-forming process. That’s why we want to redistribute as much material as possible until we get the material to where we need it. This is possible with the very comfortable and efficient technology of the new forging roll. And this is also where the process essentially differs from traditional die-forging, in which relatively much material is wasted by the indispensable flash.
up grade: This further development of stretch rolling respectively roll forging was the specific requirement you made to LASCO. Has it been met?
Aalderink: Yes, it has – at least as far as our technical specifications are concerned. Now we are challenged by our own product development, which had been limited by the technical possibilities of the forming units so far. The new forging roll enables us to gener-ate completely new products that are feasible as far as production technology is concerned. Thus the correct answer is: As matters stand we think so.
up grade: Has the new development already passed its acid test?
Aalderink: As already said: It’s actually up to us to furnish proof of it!
up grade: How big do you think has your edge over the competition become now?
Aalderink: It is important to us to point out that we have great respect for our colleagues in this industry. Therefore I would not like to talk about an „edge over” them. We are following a strategy aiming at niches by having increasingly specialized in suspension systems. The new technology allows us to manufacture unique products of which we expect USPs.
Challenge
Roll forging with process-integrated, dynamic roller gap adjustment
– that’s absolutely new. The Dutch spring specialist VDL Weweler is
the first user of this technical advancement. After some months of
practical experience Weweler is more and more convinced that the
new RCW 630 So is a milestone for spring rolling.
Dynamic roller gap adjustment on the RCW 630 at VDL Weweler in Apeldoorn (Netherlands).
Interview
Dick G. AalderinkManaging DirectorVDL Weweler B. V.Apeldoorn, Netherlands
The short form „So” in the LASCO type
designations stand for „Sonderausführung”
(„special design”). The subtle difference
compared to standard designs of the forging
roll series „RCW” is the dynamic roller gap ad-
justment. It is required that rectangular steel
billets can be rolled on both ends in the shape
of an exactly defined parable without the
profile width changing significantly. LASCO
developed the new technical feature in close
coordination with the first user of this innovati-
on, VDL Weweler.
As spreading cannot be avoided in flat rolling
with a tool without profile, it must be com-
pensated by upstream or downstream upright
rolling. Depending on the tolerance require-
ment flat or upright rolling will be repeated
several times.
The basic design of the special longitudinal
rolling machine corresponds more or less
to the RCW series. The dynamic roller gap
adjustment is effected via two hydraulic
cylinders which are coupled with one of the
two bearing housings of the upper roller each.
The roller diameter is 630 mm, the maximum
rolling force 2000 kN. A specially adapted
and programmed industrial robot takes over
the function of the manipulator.
To be able to guarantee the necessary repea-
tability of the roller gap at a rolling speed of
up to 500 m/sec and a roller gap adjustment
speed of 100 mm/sec, the hydraulic system
with proportional control technology had to be
developed especially for this application.
Two standard tools are arranged next to each
other on the rollers: a contourless flat tool as
well as a tool with flute-type contour. During
the rolling pass the roller gap is adjusted syn-
chronously to the roller rotation in a compu-
ter-controlled way.
The RCW 630 provides reliable services in
the new plant of VDL Weweler in Apeldoorn
(Ecofactory). The enterprise, which belongs
to the internationally established VDL Groep,
develops, produces and sells air suspension
systems for trailers, trucks and busses. Ano-
ther business area is the development of lift
axles and parable springs.
A subtle differenceAcid test at Wewler