Annual report 2009 - Siempelkamp

task. Siempelkamp has more than 125 years of experience in designing and building large presses. The engineers’ designs handle the
large forces which occur during crimping, straightening and forging processes. For each new press our engineers benefi t from the
knowledge gained from previous comparable orders. In this way, they develop the optimum solution for the current customer.
This know-how is not only retrieved for new orders, but also for upgrading tasks. After an operation period, in some cases, of more than
50 years, the life expectancy of many central press components (e.g., beams and foundation stands) is almost reached. When it comes
to replacing these parts and upgrading the equipment with state-of-the-art technology, Siempelkamp is commissioned. We are just as
committed to modifi cations and upgrades to existing presses as we are to completely new press concepts. Here, we trust in our ability
to unerringly analyze designs from earlier decades, to carry out calculations according to the Finite Element Method (FEM) and to
optimize the design with state-of-the-art technology. The development of Prod-IQ ® Metal Forming is new to Siempelkamp: This
software ensures the optimal operation of the press and reduces costs.
the foundation stands made of nodular graphite cast iron in the
company-owned foundry in Krefeld. Ten of these castings weighed
between 200 and 250 t each (220 and 275 US tons).
The following fi nish-machining of the large parts was carried out
by Siempelkamp in Krefeld. One of the world’s largest portal milling
machines was used to precisely reach the fi nal dimensions of the
parts. With the 450 MN closed-die forging press Alcoa produces
structural parts made of aluminum for the aircraft industry, such
as fuselage frames with sizes up to 6,000 x 2,000 mm (20 x 6.5 ft).
The goal of the modifi cation is to turn this 450 MN press into the
most state-of-the-art and effi cient forming press in its class.
Because of its large press force and its central meaning for the
American aircraft industry, the giant press has become a “National
Historic Mechanical Engineering Landmark” in the United States
of America.
Another casting during machining
Siempelkamp Machinery and plants
Prod-IQ ® Metal Forming at Fabtech 2009
At Fabtech in Chicago in 2009 Siempelkamp presented the new
software package Prod-IQ ® for the process modeling and online
quality control of its metal forming presses. The fi rst real-life
results prove that users save up to 2.5% in material and that
downtimes have been reduced by up to 4%. Key data include:
• suitable for all Siempelkamp presses including plate forming,
open-die forging, and closed-die forging presses
• collected data is presented with the help of clear graphics
• quick availability of need-driven information leads to higher
transparency
• characteristic data regarding plant performance, quality,
resource consumption, and costs can be analyzed during
production
• exact traceability of all production steps is guaranteed
• specifi c requests pinpoint the reason for costs
effi ciency increase
• optimized production and processes
• implementing of the most cost-effi cient, condition-dependent
maintenance strategy
Metal forming
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