FORGING

The purpose of this new 20 meter high facility was not to establish a new world record as an end in itself, but to gain specific benefits. The targets that were achieved include a duplication of the production capacity, an extension of the product line plus cost-effective operation. In addition, higher production will in the medium term create 100 new qualified jobs at Böhler Schmiedetechnik.
The new Eumuco-Hasenclever screw press is part of a major investment scheme worth around EUR 28 million. In addition to the screw press, which including the foundation block weighs more than 6,000 tons, a new rotary hearth furnace, a die preheating furnace, manipulators and the necessary infrastructure for the facilities were set up. Böhler's decision to install a clutch-operated screw press was based on both quality, strategic as well as economic aspects.

Intelligent forging concept with combined benefits

Eumuco-Hasenclever's clutch-operated screw press allows the application of high deformation forces while minimizing the contact time of the forging. This technology thus combines the benefits of a forging hammer with those of a hydraulic press while avoiding their disadvantages. With a forging hammer, the forgings made from high-strength steel grades would for process reasons heat up excessively and have a negative impact on the microstructure. If the forging hammer's impact force were reduced, this would require, for example, 100 blows, while the clutch-operated screw press needs just a few press operations to achieve the required plastic deformation. Hydraulic presses have a much higher pressure-contact time due to their low deformation speed. Workpieces therefore loose their temperature on the surface, which may lead to an inhomogeneous microstructure over the component cross-section. In view of the products to be manufactured at Böhler, the clutch-operated screw press hence constitutes the ideal machine concept.

Certified forging process for sophisticated steel grades

Böhler Schmiedetechnik mainly produces high-performance components made from special steel grades and titanium and nickel-based alloys for the manufacture of aircraft, jet engines and turbines. For these applications each individual component must undergo a comprehensive quality control and documentation. Accordingly, production processes must also be certified to comply with stringent rules. As Böhler Schmiedetechnik already has the screw press technology, they were able to use this experience in the certification process and to thus clearly minimize the time needed for new approvals.

Highest forging performance, yet efficient and flexible

The huge deformation potential of the clutch-operated screw press is provided by the main flywheel which has a diameter of 7.5 meters. It stores the energy of the press and rotates at a speed of 36 revolutions per minute, having a moved mass of 590 tons. Integrated in this flywheel is the clutch with a closing force of 40,000kN, which during deformation transmits a torque of around 60,000kNm to the screw. Within a few milliseconds after achieving its maximum force, the clutch opens and separates the flywheel from the screw. Despite the world's largest deformation force for clutch-operated screw presses, the machine needs only 500kW of frequency-controlled drive power. Compared with conventional type screw presses, this is a reduction of around 87% which is accompanied by a significant increase in deformation energy. Another special feature: the impact speed is variable between 0.25 and 0.5m/s without any loss in deformation force. This allows the forging of much larger components than before, making it possible for Böhler Schmiedetechnik to cope with the rising demand from the aircraft industry in a more flexible way and in line with requirements.

Gigantic castings and elaborate logistics

It is not only the power of the facility that sets a new record. Its components too mark a superlative in industrial plant design and construction. They were manufactured by European specialist companies under the supervision and according to the engineering of SMS Meer (Eumuco Hasenclever Product Unit). For example, the press table weighing 305 tons was made from a single block that had been cast from around 600 tons of liquid steel. At 340 tons, the cross-beam is the heaviest component of all. Just one of the four tie rods that is used to prestress the press weighs 75 tons, including nuts. The production and machining of these gigantic components represented an extreme challenge. The majority of the core components, whose quality is a decisive factor, as well as the precision components were manufactured in the workshops of the Eumuco Hasenclever Product Unit of SMS Meer. Experts from Eumuco Hasenclever were also responsible for the logistics. In cooperation with heavy-goods transport contractors the huge components were taken to their destination by ship, special railway wagon and on gigantic trucks, using selected routes on some of which bridges had to be specially reinforced and the width of tunnels extended.

Perfect teamwork and excellent start of production

SMS Meer's Eumuco Hasenclever Product Unit started to work on the design and manufacture of the screw press in January 2005. At the beginning of 2007 the comprehensive test program could be started and production was successfully begun as early as in July 2007. All in all, completion was just 14 days behind the originally planned project time schedule. An excellent result for a project of this magnitude. It was made possible through the close cooperation with Böhler Schmiedetechnik right from the planning stage. Another reason for the success is the smooth interdisciplinary collaboration of the well-established project teams at Eumuco Hasenclever. This way the huge components weighing tons, the 24 kilometres of electrical cabling and 500 meters of pipework could be installed precisely fitting and on time. The result: the world's most powerful mechanically operated forging press with a press force of 35,500 tons is now working reliably in a tough production environment.

Technical parameters

Maximum press force: 35,500 tons
Screw: 82,000 kg / 1,320mm diameter
Table weight: 305,000kg
Cross-beam weight: 340,000kg
Tie rods with nut: 75,000kg / 16m long
Flywheel: 590,000 kg / 7,500mm diameter
Lube oil: 11,000 liters
Hydraulic oil: 5,000 liters
Total weight: approx. 3,000 tons
Spring-supported foundation block: approx. 3,000 tons

SMS group:

SMS AG is the holding company of a group of international companies engaged in the design and construction of plant and machinery for the processing of steel, NF metals and plastics. Under the roof of SMS metallurgy, the group is divided into the Business Areas SMS Demag and SMS Meer on the one hand and SMS Plastics Technology on the other hand. In the year 2006, approx. 9,000 employees worldwide generated sales totalling around EUR 2.8 billion. SMS Meer ranks among the world's leading designers and manufacturers of plant and equipment for the production of tubes, long products and forgings.

Böhler-Uddeholm group:

Böhler-Uddeholm is an internationally leading producer of stainless steel products with headquarters in Vienna/Austria. The group is the world leader in tool steel and a few other niche products such as small and medium-sized forgings for the aircraft industry. In the 2006 financial year, Böhler-Uddeholm's staff of 14,000 generated sales of EUR 3.1 billion. Part of its Division Special Forgings is Böhler Schmiedetechnik GmbH & Co. KG in Kapfenberg, Austria, whose customers include leading aircraft and turbine manufacturers and companies from the power generation industry.

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