SMX hydraulic radial forging technology, designed and built by SMS group, is particularly suited for the aerospace industry, where high-quality forged components are essential. This technology offers specialized forging capabilities, including high penetration, executing large manipulator steps, and ensuring superior core deformation and strain rate control. These features are important for producing high-quality components, especially when working with high-strength alloys and challenging materials like titanium. SMX hydraulic radial forging technology, ensures the reproducibility of products and achieves a high degree of automation. By integrating automation and precise control systems, SMX enhances the consistency and quality of forged parts.
The innovative hydraulic drive system at the core of SMX technology has been significantly developed by SMS group, integrating essential components into a compact, pre-assembled unit. This design not only reduces spatial requirements, but also improves energy efficiency by optimizing system performance.
New compact drive concept: A new space optimization solution for hydraulic systems, enhancing both safety and process stability
For radial forging machines, the choice between hydraulic and mechanical drive systems impacts the efficiency and quality of the forging process. Hydraulic drive systems offer a more adaptable approach to managing the resistance of the material during deformation, ensuring better deformation and enhancing workpiece quality. Through continuous development at SMS group, the hydraulic drive concept has been optimized to offer advantages in spatial efficiency and assembly times within the hydraulic room. The new compact drive concept requires significantly less space, as essential hydraulic components are integrated into a compact, pre-assembled unit, thereby streamlining the installation process and reducing the time and effort needed for on-site assembly. These innovations not only reduce costs and improve energy efficiency but also guarantee the reliability and safety of material through meticulous process control.
Energy-efficient innovation: Dual pump system with integrated flywheel and frequency inverter
Central to SMS group’s innovation is the dual pump configuration, where a single motor drives two main pumps. This design enhances efficiency by reducing the number of motors needed. A flywheel is integrated into the motor pump together with a frequency inverter. The flywheel acts as a mechanical energy buffer and eliminates electrical peak loads. The frequency inverter allows the pumps to operate at an ideal efficiency level, enabling the motor to be downsized. By that, peak load on the electric grid can be reduced significantly resulting in overall reduced OPEX costs.
Advantages of hydraulic drive systems over mechanical drive systems
Mechanical drive systems typically operate with fixed penetration speeds, limiting adaptability to different material requirements. The stroke of a mechanical drive influences the penetration speed into the material, but this speed can only be adjusted in a very narrow range. Consequently, mechanical systems may struggle to accommodate the specific needs of different materials.
Hydraulic drive systems provide flexible control over the penetration speed. With the hydraulic system, the ram speed can be adjusted to achieve the desired speed, allowing for precise manipulation of material deformation. This flexibility is important when working with materials such as titanium or Ni-base alloys, where controlled deformation is essential to achieve optimal mechanical properties. Rapid and slow penetration speeds can lead to varying strengths and microstructures.
Why controlled material deformation is important for certain manufacturing processes
A flexible approach to managing material resistance during the deformation process is particularly crucial for aerospace-relevant materials such as titanium and Inconel, where the range of applicable forming conditions is very narrow. The hydraulic drive allows for precise control of the velocity, position, and force, unlike the stroke of a mechanical forging machine, which is always identical as it is determined by the eccentric drive. Further, the precise control capability offered by the hydraulic drive concept enables homogeneous temperature distribution and reduces the risk of material surface cracks. For instance, titanium can develop an undesirable grain structure, commonly referred to as a “spaghetti structure,” if the deformation speed is not appropriately selected. Only a hydraulic drive provides the necessary control.
By precisely managing the material deformation process, manufacturers can achieve the desired mechanical properties and microstructures, which are essential for the reliability and safety of high-performance materials such as titanium and Inconel. This control helps prevent defects and inconsistencies that could compromise the functionality and longevity of the final product.
Automated line control enhances precision and efficiency in aerospace forging processes
The production of aerospace components from nickel-based and titanium alloys requires precise process control. These materials demand meticulous forging processes to ensure optimal mechanical properties and microstructures.
Typically, this involves a forging line that includes an open-die forging press and a radial forging machine. The integration and precise coordination of these machines are crucial for achieving the
desired product properties, ensuring components are forged to exact specifications for improved overall quality and performance.
SMS has implemented an automatic line control system, covering all long forging products requiring high automation and capacity, which automates machine operations and integrates material handling and tracking between furnaces, open-die presses, and radial forging machines. This system enhances process control and reduces human error, moving towards “operator-free forging” and maximizing efficiency and precision.
SMS group supplies complete forging lines with tailored solutions and digital integration
SMS group is the only plant manufacturer capable of delivering a complete forging line from a single source. This includes high-speed open-die forging presses, SMX hydraulic radial forging machines, forging manipulators, and an integrated production control system. The ability to source a complete forging line offers customers advantages in terms of efficiency, customization, and digital integration.
Comprehensive service package: This ensures that all components of the forging line work harmoniously together.
Accelerated delivery: By sourcing all equipment from a single supplier, customers benefit from faster delivery times.
Simplified commissioning: Customers experience a smoother and quicker commissioning process, allowing for earlier production.
Tailor-made solutions: The broad portfolio of SMS of mechanical and service equipment allows for greater flexibility in designing custom solutions to meet specific customer needs.
Digital integration: The ability to integrate digital solutions throughout the forging line facilitates better monitoring, control, and optimization of the production process.
Uniformity of spare parts: Having uniform spare parts across the entire forging line simplifies maintenance and reduces inventory costs. This consistency ensures quicker repairs and replacements, minimizing downtimes.