Siempelkamp: The specialist for closed-die forging presses for aluminum

Krefeld, Germany, August 20, 2014 – Siempelkamp closed-die forging presses with press forces between 15 and 500 MN provide the optimal solution for numerous application areas. When manufacturing turbine disks for aircraft construction or the power plant industry and aluminum rims for the automotive industry, Siempelkamp closed-die forging presses offer a high degree of precision and efficiency due to the integrated control between complex systems. The presses always offer the perfect balance between standardization and customer-specific solutions. At Aluminum Fair 2014 Siempelkamp will present its comprehensive product range.

Many customers have already experienced Siempelkamp's expertise in regard to aluminum processing. Alcoa ordered three closed-die forging presses with press forces between 4,500 and 7,200 t for the Köfem plant in Szekesfehervar, Hungary, in 2009. With the complete forging line Alcoa produces aluminum rims for trucks. The 4,500 t block press forges unfinished aluminum blocks at a temperature between 350–520 °C. The blanks created during this process are then formed in the second press to unfinished wheel rims with a press capacity of 7,200 t. The finishing press sizes the rims to their final form.

Modernizations by Siempelkamp

A decisive reason to order from Siempelkamp was Alcoa’s good experiences with Siempelkamp presses operating in different factories. The Krefeld company has supplied more than 20 similar presses which are characterized by their high reliability and long lifespan. The long-standing relationship with the customer culminated in the modernization of the 45,000 t closed-die forging press at Alcoa in Cleveland in 2009. With this press, one of the largest closed-die forging presses in the world, Alcoa manufactures structural parts made of aluminum and tempered steels for the aircraft industry.

Within the framework of the order, Siempelkamp analyzed the design from the 1950s, carried out calculations according to the Finite-Element-Method and optimized the construction according to the latest technology and a given maximum component part weight. The result are parts that are fatigue-endurable due to their modern design and their material characteristics. The manufacture of the cast components was also part of the Siempelkamp package. Siempelkamp is the only supplier of large presses that is able to manufacture the heavy components for the presses made of fatigue-endurable nodular graphite cast iron in the company's own foundry.

Largest closed-die forging press built in Germany

In December 2012 the Chinese Nanshan Group ordered from Siempelkamp a 50,000 t closed-die forging press for the manufacture of forged parts made of aluminum and titanium alloys for the Chinese aircraft industry. To date this is the largest press built in Germany. Siempelkamp was commissioned with the design, construction and installation of the complete system. The technical data of the press: Due to the large dimension of the 4 x 7 m (13 x 23 ft) press table and the customer’s request for easier accessibility to the working area, the clearance between the columns amounts to 5 x 3 m (16 x 10 ft). Eight cylinders are responsible for the movement of the moving beam. With an output of roughly 24 MW the energy-efficient oil-hydraulic drive, developed by Siempelkamp, applies a pressure of 450 bar.

Another highlight of the press: The innovative strain rate control compensates high eccentric loads. It also allows extremely low forging speeds for the forming of very challenging geometries and materials used in the aerospace industry. The basis for this was a complex simulation which represented the mechanical structure of the press, its complete hydraulics system and its automation technology with all control structures. This press, and another 12,500 t Siempelkamp press, are scheduled to start operation in early summer of 2015.

Siempelkamp modernized the "Super Giant" at Alcoa, Cleveland

Based on Siempelkamp information