Fully automated and flashless forging
Turkish manufacturer of high-quality forged products, PARSAN Makina Parçaları Sanayii A.Ş. in Pendik-Istanbul, Turkey, has commissioned SMS group to supply a fully automated closed-die forging press. The new press of the type AMP 2500 will feature a pressing force of 25 MN and be capable of forging up to five million parts per year.
Among other things the closed-die forging plant will be used to produce pistons and flanged hubs weighing up to four kilograms in up to five forming operations.
PARSAN opted for SMS group as system supplier due to its established reputation and experience as a supplier of fully automated manufacturing lines from a single source. Key factors for awarding the contract to SMS group were the technical advice provided throughout of the project, the fact that SMS group manufactures the equipment in-house and the ability to provide the entire process technology.
The new closed-die forging press of the type AMP 2500 will be equipped with an automatic electrically driven walking beam, mechanically coupled and retractable die spraying system, programmable ejectors as well as die holder with quick die-change system. One special feature is the automatic electric walking beam type EHA of SMS group comprising four individual housings with the drive fastened to the outside of the press frame, thus ensuring that contamination from scale and dirt is prevented. The automatic system guarantees a finely balanced and smooth motion. To achieve this, EHA features a separate drive consisting of servo motors with dedicated gearing for each axis. The three axes of motion of the automatic electric walking beam are transport step, lifting/lowering and opening/closing. Travel, speed, acceleration and deceleration of the individual servo axes are automatically synchronized. The EHA walking beam system provides a very short cycle time whilst minimizing any shock loads on the mechanical elements by the application of optimized acceleration and deceleration curves during each movement. Simultaneously, the transfer sequence of the EHA is maximized for efficiency by constant monitoring of the position of the press ram. The press stroke is triggered by the automatic walking beam.
Another special feature of the press is the pivotable spray manipulator type SE located on the back of the press. This arrangement means the die holder with dies is freely accessible from the front. The spray manipulator SE is controlled in accordance with the ram movements by mechanical coupling thus ensuring the position of the system corresponds precisely at all times to the position of the ram and walking beam. The spraying times for individual processes are individually programmable. For retrofitting measures and maintenance work the manipulator can also be swiveled out of the press area.
PARSAN, a company of Güris Holding Industrial Group, was founded in 1968 and operates a closed-die forging facility on a 91,000 square-meter area, consisting of the forging shop, heat treatment equipment, finishing line and toolmaking facilities. They process materials such as carbon steel, QT steel, micro-alloyed steel, stainless steel and customer-specific steels. As a certified manufacturer, PARSAN produces predominantly for demanding, international customers from the commercial/passenger vehicle, industrial engine, agricultural machine and tractor sectors. With the new closed-die forging machine supplied by SMS group, PARSAN will noticeably increase the annual production capacity of forged high-quality components.
PARSAN Makina Parçaları Sanayii A.Ş., which is one of the most important forging parts suppliers of Turkey and Europe's automotive and machine manufacturing sector, is establishing one of the largest European manufacturing plants for engine, drivetrain and large forging parts at the Kocaeli, Dilovası site in Turkey.
The new 25-MN closed die forging press will be installed in the new PARSAN Dilovasiı factory.
The SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry. Its 14,000 employees generate sales of over EUR 3.3 bn.