Products
FORGING SHOP
All the forging shop plant is situated in the so-called old and new buildings. The former is
the original factory, to which the new was added to accommodate the growing production.
The old building houses friction, hydraulic and crank forging and fettling presses of capacities (forming force) from 0.7MN to 25MN, the heat treatment shop, the staining technology, the
surface defects repair centre and output inspection.
Also the machines installed in the new building include friction, hydraulic and crank forging and fettling presses. The principal technologies in the new building include two automatic robotised forging lines designed for forging car parts. The new building includes a fully automatic materials warehouse.
The forging plant product range includes aluminium and aluminium alloy forgings. For input,
circular and flat bars and shaped sections are used. The production of forgings starts in the production materials warehouse, where the bars are kept after input inspection. Once a certain product is launched into production, the respective material is released to the cutting shop,
where lumps of material of defined size (the so-called stock) are cut. Only the automatic lines
in the new plant work differently, as these are fitted with integrated sawing machines. After
cutting, the stock is deburred and cleaned. The basic production technologies include free and
die forging. The operation is a complex forming process influenced by many factors (input
material quality, stock and die temperatures, lubricant composition and density and, last but
not least, labour skills). Every forging press includes a linear or carousel furnace, in which the
stock is heated to the forming temperature. The desired die temperature is achieved with gas
or oil burner heating. The forging is followed by fettling and deburring operations, heat treatment (hardening or artificial ageing), calibrated and for some, the surface finish is applied (staining). Finally, the finished products are inspected to meet their specifications .
For inspection of specific car components (axle arms) the forging shop includes a straightening and penetration line. In the first step, the part is straightened to the desired straightness specifications and in the second they are inspected on the penetration line. Penetration is a capillary inspection technique for the detection of surface defects.
The products are either shipped to the customers directly, or distributed after machining in the Milling Shop within the framework of the consortium co-operation.
MILLINGSHOP
The shop is outfitted to carry out the following technological processes:
A) CHIP REMOVAL TECHNOLOGIES
Machine tools:
1. Conventional machine tools
Drilling machines, lathe, general purpose mill- short run production,
simple operations
2. HECKERT CNC machines
- designed for mass production, boring, milling and drilling operations
Specifications:
range (X,Y,Z) 700/500/500
tool holder capacity 1x 30 tools
system CNC 600-3
3. CNC machines
MCV 750/500 machining centres - for demanding bulk production
Operations: drilling, reaming, boring, milling, tapping, 3D milling,
including programming services
Specifications:
range X,Y, Z axes - 750/500/500 mm
table capacity 300 kg
spindle speed 20-8000 rpm
tool holder capacity: 20 tools
heidenhain 426 Control System
Double spindle machining centres BA 25/2 - for bulk production
CNC table tilt control as another programming axis
Specifications:
spindle spacing 300 mm
table area ( X,Y) 700 x 450 mm, (left- + right-hand)
tool holder capacity: 2 x 36 tools
Siemens " Sinumerik 820" Control System
Three-shift production. The machine tools and tooling are geared for wrought aluminium parts production. 3D measurement inspection. The product range includes mainly parts for the car industry (AUDI, BMW, MZ, ŠKODA).
B) GRINDING
Manufacturing of wrought aluminium parts requires grinding applications for
surface finishing operations. This is why our workshop is outfitted with new
LOSER belt grinding machines used for both roughing and final surface finishing.
C) TUMBLING
To improve the surface finish of wrought aluminium parts, circular vibrators
from ROSLER with ceramic impact pebbles are used. The operation ensures
clean surface free of burrs featuring higher corrosion resistance.
Machine Circular vibrator R 620 EC
TOOLS SHOP
The forging tools drawings are based on the part drawing approved by the customer. Using the I-DEAS software, the CAD design of the 3D model of the forging tool cavi-
ty is made together with the CAM control programme for the CNC milling machine, which later cuts the tool cavity in the graphite electrode or the plastic copy tool. The graphite electrode is used in the electro erosion manufacturing of the desired shape in the heat-treated steel block.
In case plastic copy tools are used, milling and subsequent heat treatment of the forging tool in vacuum hardening furnaces is used.
The finished tool is measured on a 3D measuring device.
Besides forging tools, our range includes also
fettling and calibrating tools, machining and measuring fixtures, moulds for plastics and
other tools.
