RADIAL FORGING MACHINES SMX - SMS Meer

RADIAL FORGING MACHINES
SMX
All-round pioneers
SMS GROUP
Leaders in plant construction
and machine engineering
The SMS group unites global players in the construction of plants and machines for the processing of steel and NF
metals, operating under the roof of SMS Holding GmbH. It consists of the two business areas, SMS Siemag and
SMS Meer, as well as industrial participations. SMS Holding GmbH is responsible for strategic planning and control.
The sole owner of the SMS group is Siemag Weiss GmbH & Co. KG, the holding of the Weiss entrepreneurial family.
FAMILY-OWNED AND
WORLDWIDE PRESENT
As a family-owned company, the SMS group has
built on solid values and a culture of responsibility
for four generations. It holds a strong market position,
while its decentralised structure ensures a fast and
efficient response to individual customer demands.
The SMS group combines the flexibility of company
units that operate as medium-sized enterprises
with the broad resources of an internationally active
company – all to the benefit of the business partners.
The decentralised corporate culture ensures that not
only the individual units, but also the employees
always think and act in an entrepreneurial manner.
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BUILDING ON A STRONG BASIS
A long-term view, careful financial management, the
focus on values, plus an understanding of the cycles
of the machine and plant construction market have
guided the group’s strategic planning for decades.
Also high on the agenda are investments in the
areas of energy and environment technology, service
and modernisation of plants as well as on-the-job
training and qualification of core employees. On this
basis, the SMS group creates tailor-made plant
solutions which enable its business partners to keep
well ahead of the competition.
SMS MEER BUSINESS AREA
The SMS Meer Business Area bundles its activities
in the fields of steelmaking plants and continuous
casting technology (long products), tube plants, long
product rolling mills, forging technology, nonferrous
metals plants, heat treatment technology and
service. Starting with advisory services, followed by
implementation and commissioning, and finally
modernisations – the employees of the business
area always combine their specialist knowledge with
approachability and flexibility.
TOP QUALITY
The innovative solutions provide our customers with
measurable benefits in their challenging markets.
Whether steel for automotive parts, pipelines, heavy
structural profiles, wheels for high-speed trains or
aluminium for façade structures: the machines and
plants tailored by the SMS Meer Business Area
ensure the cost-efficient and flawless production of
the necessary components.
INDIVIDUAL SOLUTIONS
The SMS Meer Business Area concentrates the competence of globally successful specialist firms under
one roof to create a unique, full range of supplies and
services for metal processing and associated fields.
In doing so, the employees focus consistently on the
needs of their business partners. They find individual
solutions and fulfil the plant operators‘ expectations,
both flexibly and reliably. This is verified by 17,000
successful reference projects the world over – in the
last 50 years alone.
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RADIAL FORGING MACHINES
Our strengths – your advantage in the market
Bar forging
GREATER COMPETITIVE EDGE
The requirements of the forging industry are simple:
high precision and productivity, perfect structural
properties and flexibility in terms of use, batch size
and unit production. SMS Meer not only meets the
demands of today, but also ensures that plant owners have a greater competitive edge to safeguard
their future. Hydraulic radial forging machines SMX
are global leaders thanks to their innovative design,
high performance and intelligent technology. The
main advantage of radial forging machines is that
the workpiece is enclosed by four forging dies and is
therefore only able to yield axially, thereby avoiding
lateral spread.
WIDE RANGE OF APPLICATIONS
In terms of the range of both materials and forms, it
is the shear versatility of SMS Meer‘s radial forging
machines which customers find so appealing. The
list of suitable materials includes, among others, ​
carbon steels, structural steels, tool steels, highspeed steels, stainless steels, non-magnetic steels,
nickel-based alloys and titanium alloys.
Forgings of Inconel 718
Semi-finished products for rolling mills
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Zirconium, tungsten, molybdenum and other special
alloys can also be forged. All types and sizes of
ingots, round and rectangular slabs as well as hollow
components can be used as forging stock.
THE RESULTS
High-precision products of outstanding metallurgical
quality, with perfect compaction to the core and fine
grain through the entire cross-section are created
from the input stock. The tolerance factor, depending on the outside dimension and product, ranges
between 0.0125 and 0.0075.
LISTED BELOW ARE SOME OF THE
FORGING PRODUCTS POSSIBLE:
„„ Bars – round, square and flat
„„ Multi-stepped shafts
„„ Axles and drive spindles
„„ Thick-walled tubes.
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INTEGRATED
PLANT CONCEPT
One-stop shop
HARMONIZED INTERFACES
SMS Meer offers everything – from the mechanical plant components, hydraulics and electrics to the automation
systems – from a single source. So customers receive technologies which are perfectly adapted to each other, thus
ensuring high plant productivity right from the start.
THE MAIN COMPONENTS
A typical plant configuration comprises the following: Radial forging machine SMX, press frame
with four hydraulic cylinders and tools in an X-shaped arrangement.
„„ Two manipulators
„„ Hydraulic units
„„ Loading, unloading and transportation equipment
„„ Control equipment with control panel, pass schedule computer and switch-gear cabinets
„„ Tool changing equipment
„„ ComForge technology package
„„ Cutting and marking machine.
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RADIAL FORGING MACHINE SMX LAYOUT
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PIONEERING TECHNOLOGY
Better fully hydraulic
CUTTING-EDGE ENGINEERING
The heart of the radial forging machine SMX comprises a highly rigid press frame in which four
hydraulic cylinders with corresponding tools are
arranged in an “X” form. SMS Meer’s solution is
impressive thanks to its clear, simple and easily
accessible design.
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HIGH DEGREE OF ENCAPSULATION
Each of the four hydraulic cylinders has a relatively
short maximum stroke, allowing rapid backward
and forward movement. The encapsulation of the
workpiece (normally between 70 and 90 percent) in
conjunction with the high number of cycles of the
hydraulic cylinders ensure a high degree of forming
and a freely adjustable deformation ratio suited to
the material. The degree of encapsulation of the tools
substantially improves formability.
UNIVERSAL AND FAST
The four forging dies move synchronously with the
centre of the press, at the same time deforming the
ingot with their tools. The required forging accuracy
is achieved through precise, highly dynamic control
of the hydraulic cylinders. Depending on the workpiece, the four dies can also be used in sequence
– that is, one pair after the other. In the case of
extremely flat ingots, rectangular cross-sections or
when forging round bars with high pass reduction
using the conventional round die process, a machine
like the open-die forging press can be operated with
just a single pair of dies. The maintenance-friendly
design means the tools can be changed in no time
at all.
THE ADVANTAGES AT A GLANCE
„„ High productivity
„„ Energy-efficient with just one forging heat
(as a rule)
„„ Guarantee of forming right to the core
„„ No risk of molten core adhesions
„„ High surface quality
„„ Fine grain with even compression right to
„„
„„
„„
„„
the core
No tool change for cross-section reductions
of between 6.25 and 11.0
Quick refit times thanks to the tool quickchange system
Variable positioning of the tools
Low wear and low-maintenance design.
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INNOVATIVE HYDRAULIC
CYLINDERS
Maximum performance with stroke sequences
Pilot
Servo valve
Po
Ps
Q
Ps
40 bar
Constant
Po
350 bar
Q
Constant
Q
PC
PC
Q
Push Back
Q
Push Back
Q
Push Back
Return
Start position
The virtually maintenance-free press cylinders feature
patented technology from SMS Meer. The basic
principle: A servo-controlled pilot cylinder which is
followed by the working piston. The deformation
rate, return stroke and high forging accuracy of each
forming stroke can be controlled by means of the
pilot cylinder. The high-pressure oil flows constantly
in one direction – from the pumps through the pipes
and then through the working cylinder, which performs the stroke movement in the press direction.
During the return stroke movement, the working
cylinder is moved via retraction accumulators, while
the oil flows through the internal forging valve and
cools the cylinder shaft and tool. This even flow of oil
Q
Ps
40 bar
PC
Q
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Servo valve
Servo valve
Po
40 bar
Pilot
Pilot
Return
Forging
Q
Retraction
results in low-vibration operation with small working
strokes, a small compression volume and up to
300 strokes / min.
THE ADVANTAGES
AT A GLANCE
„„ Vibration-free operation, low sound level
„„ Up to 300 stroke sequences per minute
„„ Intelligent design
„„ Extremely long maintenance intervals.
Constant
Return
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COMPACT PLANT LAYOUT
Simply strong
4
7
5
12
3
1
2
6
1
3
5
7
Forging machine
Pilot valve
Hydraulic drive
Sliding bases 2
4
6
Forging cylinder
Manipulators
Gripping tongs
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PRECISE MANIPULATORS
Forging quickly and uniformly
COMPUTER-CONTROLLED
MOVEMENTS
In addition to the high load-bearing capacity, precise
interaction between the manipulators and press is
crucial for ensuring a perfect forging result. This is
only possible with a sophisticated, computer-controlled system.
WORKING IN HARMONY
SMS Meer has automated the motion sequences
of the manipulators for a fast, even forging process.
On receiving the first workpiece, the first manipulator carriage moves continuously forward and guides
the workpiece precisely into position in the press.
During the steady forward motion of the carriage, a
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mechanism ensures the tongs unit remains stationary, in sync with the strokes of the forging tools. The
rotation of the tongs is also very precisely aligned
with the strokes. Here, too, computer-controlled
synchronized operation takes place as soon as
the second manipulator grips the workpiece. Both
manipulators are able to exert a certain tensile force
on the workpiece as the forging tools are being
entered.
FOR SOLID AND HOLLOW BODIES
The tongs are hydraulically actuated and have a high
clamping force. The tongs peel assembly is designed
as a hollow shaft structure, thereby enabling the use
of a mandrel forging device, e.g. for tubes.
THE ADVANTAGES
AT A GLANCE
„„ Computer-controlled manipulator movements
„„ Synchronized with forging strokes
„„ High load-bearing capacity
„„ Compact design
„„ Maintenance-friendly designs.
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COMFORGE
Intelligent technology package
LARGEST MATERIAL DATABASE
With data on over 400 materials (and increasing),
SMS Meer’s ComForge technology package has
everything required for drawing up relevant forging
schedules for all customers. If a customer’s alloy
does not correspond with any of the existing material
families, new flow curves are compiled in close
collaboration with RWTH Aachen University. In this
way plant owners benefit from the most comprehensive database for trouble-free, technologically
proven forging processes.
CALCULATING, CONTROLLING,
CHECKING
ComForge is the technology package for calculating
pass schedules, taking account of the cross-sections
and forging sequences. All desired parameters can
be input easily via an intuitive user interface.
„„ Geometry of the initial and final dimensions
„„ Material quality of the forging
„„ Tool and machine parameters
„„ Deformation parameters
„„ Specific customer requirements
(e.g. fine-grained structure)
„„ Furnace temperature.
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AUTOMATION CONCEPT OF THE FORGING LINES
Visualization
Maintenance
Technology
Local Ethernet
Local Ethernet
Siemens S7-400
Customer Ethernet
Router for service
Network server
WinCC Server
Profibus 1
Profibus 2
Profibus 3
Profibus 4
Customer Profibus coupling
- Furnace unloading system
- Roller table for unloading
Programming device
Once the parameters have been set, the pass
schedules are calculated by referring to SMS Meer’s
comprehensive database. They are then transferred
to the automation system which monitors and
controls all plant components, control devices and
sensors. Examples of these are:
„„ Forging sequence from the beginning to the final
cross-section
„„ Geometry of the deformation from the initial to
the final dimension
„„ Forces and temperatures
„„ Time of each pass and overall forging pass.
The pass schedule can be optimized and saved by
the operator, such that all data for the forging process are immediately available for repeat jobs.
User interface of control software
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ALL SERIES
Flexible and successful
A WORLDWIDE SUCCESS
In the past two years alone, SMS Meer has commissioned eight radial forging machines SMX
worldwide. The productive benefits, high product
quality and the low life-cycle operating costs of the
radial forging machines SMX are the key reasons
why plant owners choose SMS Meer. What‘s more,
with over 20 years‘ experience in the field of radial
forging machine construction, SMS Meer is your
competent partner when it comes to materials and
processes.
SMX 800 in the Czech Republic
SMX 600 in Taiwan
SMX 650 in the USA
RUMX 700 in Italy
SMX 650 in China
SMX 500 in Japan
SMX 650 in China
SMX 200 in Germany
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RADIAL FORGING MACHINES SMX
Series
200 / 3
350 / 6
450 / 13
650 / 15
800 / 18
1100 / 22
Max. initial pass rounds in mm
200
350
450
650
800
1100
Smallest finished product in mm
40
60
70
80
100
120
Max. bar length of finished product in m
6
10
12
14
18
18
Max. ingot weight in t
1
1.4
3.5
6
8
10
Max. forging force in MN
3
6
13
15
18
22
Max. stroke per tool in mm
85
120
180
220
280
350
Stroke rate when planishing in 1 / min
300
260
240
240
220
200
MANIPULATORS
SMM
7 / 14
25 / 50
35 / 70
60 / 120
80 / 160
100 / 200
Max. load-carrying capacity in kN
7
25
35
60
80
100
Max. clamping torque in kNm
14
50
70
120
160
200
EXCERPTS FROM REFERENCES
Customer, city / country
Machine type
Max.
press force
in MN
Max.
Max.
ingot weight
tool opening
in t
in mm
Carpenter Technology Corporation, Tanner / USA
SMX
22
10.00
1100
Electrostal, Electrostal / Russia
SMX
12
2.50
600
Not named/Japan
SMI*
8
-
430
Hubei Xinyegang Steel Co., Huangshi / China
SMX
16
8.00
800
Vitkovice Hammering, Ostrava / Czech Republic
SMX
18
8.00
800
Wuhu XinXing Ductile Iron Pipes, Wuhu / China
SMX
13
6.00
700
Dongbei Special Steel Group, Dalian / China
SMX
16
8.00
800
Universal Stainless, North Jackson / USA
SMX
13
6.00
700
Jiangsu Tiangong, Danyang City / China
SMX
13
6.00
700
S­-Tech Corp., Sinying City / Taiwan
SMX
12
6.00
600
Top Eastern, Dalian / China
SMX
2.75
0.75
200
Baosteel Group, Shanghai No. 5, Shanghai / China
SMX
13
6.00
700
Aubert et Duval, Les Ancizes / France
SMX
13
3.50
500
Hitachi Metals, Yasugi / Japan
SMX
13
3.50
500
RUMX**
8
3.50
700
SMX
2.75
0.75
200
RUMX
10
3.50
800
Timet, Birmingham/United Kingdom
Schmidt + Clemens, Lindlar / Germany
Acciaierie Foroni Spa, Gorla Minore / Italy
* Horizontal forging machine with tools in an I-shaped arrangement
** Radial forging machine with tools shifting device
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SERVICE
Taking care of everything –
MEERcare®, MEERcoach®, MEERconsult®
The employees at SMS Meer do everything to ensure that customers are satisfied with the company’s machines
and plants for many years. The SMS Meer Service experts continue to look after them even after commissioning – a
whole plant life long. With MEERcare®, MEERcoach® and MEERconsult®, SMS Meer offers services for machines,
people and processes.
MEERcare®
Spare Parts
Service
MEERcoach®
Training &
Coaching
MEERconsult®
Consulting &
Implementation
Maintenance
Modernization
Field Service
Spare Parts
Equipment Check
Mechanical
Components
Repairs
Assessment
Fact Finding
Audits
eService
Condition
Monitoring
Hydraulic
Systems
Trouble Shooting
Standardised
Trainings
Feasibility
Studies
Spare Parts
Management
Maintenance Service
Electrical Control
Systems
24/7 Support
Individual
Training
ecoplants
Assessment
Warehousing
Remote Service
Automation
Equipment
eLearning
Strategies &
Concepts
Change
Management
Value Added
Components
Full Service
These services cover three specific areas:
„ With MEERcare®, SMS Meer offers tailored service solutions – from spare parts, through emergency
calls at short notice, regular maintenance measures through to comprehensive modernisation measures.
„ MEERcoach® focuses on the people: The SMS Meer Service experts share their know-how with the
customers and provide on-site support for the ongoing production.
„ The MEERconsult® specialists analyse processes in preparation for their optimisation.
THE RIGHT PARTS IN THE RIGHT
PLACE AT THE RIGHT TIME
The right spare parts have to be available at all times
so that production doesn‘t come to a standstill. At the
same time, capital tie-up and storage costs have to
be kept low. That is why SMS Meer delivers spare
and wear parts for all machines quickly and reliably.
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A web-based, machine-specific parts catalogue
makes the ordering process even easier. On request,
SMS Meer also takes care of the whole spare part
and stock management. The differing parts stocking
concepts are always geared to the customers‘
individual needs.
CONTINUOUS HIGH PERFORMANCE
Whether one-off fact-finding, continuous monitoring
via remote service or regular plant inspections: The
SMS Meer Service experts analyse and service the
plants. On request they even take over the complete
maintenance. Plant owners thus ensure maximum
plant availability and optimum production results.
ALWAYS UP-TO-DATE
Plant owners are engaged in dynamic markets. The
demands on profitability, product quality and
productivity have risen steadily for plant owners in
recent years. New technologies and plants arrive on
the market in ever shorter innovation cycles. Tailored
and customised modernisation concepts from
SMS Meer ensure that the plants run for decades:
and that with reduced operating costs, higher
productivity and improved product quality.
FIELD SERVICE
Even in emergencies, customers can rely on SMS Meer
Service. The Service technicians help with troubleshooting and the necessary repairs. With short reaction times and high availability, they ensure that the
plant is up and running again as quickly as possible.
CORPORATE SUCCESS THANKS TO
TECHNICAL KNOW-HOW
Whether individual or standardised trainings – the
MEERcoach® experts plan individually tailored training
programmes and implement these together with the
customer. The plant operators gain valuable knowhow through time-tested formats and special
e-learning offerings – for more operational reliability
and more efficient processes.
HIGHER PROFITABILITY THANKS TO
THE RIGHT ADVICE
More efficient processes, optimised technology and
more effective use of resources – those are the goals
of MEERconsult®. SMS Meer carries out feasibility
studies to establish a sound basis for management
decisions, or develops strategies and concepts for the
optimisation of existing plants and processes.
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CLOSE TO CUSTOMERS
Think global, act local
The Business Area SMS Meer is represented worldwide. 17,000 reference installations demonstrate the
market’s confidence in the expertise, experience,
reliability and flexibility of the company.
No matter where the customers work and what
language they speak – the right people at SMS Meer
are always on hand. In this way SMS Meer can support
its business partners quickly and effectively.
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Engineering / production
Sales / service
IMPRINT
SMS Meer, Corporate Communications, Dr. Peter Heimerzheim (Director)
Ohlerkirchweg 66, 41069 Mönchengladbach, Germany, Phone: +49 2161 350-2600, Fax: +49 2161 350-1862
communications@sms-meer.com, www.sms-meer.com
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SMS MEER
Business Unit Forging Plants
41069 Mönchengladbach
Germany
Phone: +49 (0) 2161 350-1691
Fax:
+49 (0) 2161 350-1778
hydraulicpresses@sms-meer.com
www.sms-meer.com
MEETING your EXPECTATIONS
The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics
as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation
to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.
E1201.10/ 14 en · Printed in Germany
Ohlerkirchweg 66