Annual report 2009 - Siempelkamp

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Pattern making Molding shop Casting simulations Shared engineering – for best possible customer benefi ts All departments involved in product development take part in an intensive exchange of ideas and experiences. From the beginning on we connect the frame criteria of the casting technology, such as the pouring position and allowable stresses, with the needs of our customers. We call this integrated development ‘Shared Engineering’. In order to supply our customers with the best-possible solutions, teamwork ranks fi rst for us. Furthermore, the certifi cation according to DIN EN ISO 9001 guarantees a reproducible production process in all areas of the Siempelkamp Foundry. This process offers a large degree of design freedom and allows comparatively thin and stable structures, for example, in the center of a casting as well as in highly stressed places. Varying cross sections can be streamlined in order to minimize stress concentrations. Pattern making represents the beginning of our services following the engineering: First designs lead to 3-D models which are introduced to our customers before the detailed development starts. With the help of FEM calculations, the models are stressed under simulated working conditions with static and dynamic stresses. During the next step, our engineers test the model in a prototype simulation. Thereupon, the forces, required services as well as the dimensions of the component parts take shape. According to the resulting calculations, wooden patterns are constructed which are available to the molding shop of the foundry after comprehensive testing. The next step involves the mold making. During this process, precision and cost control have to be conciliated. In order to keep the production costs as low as possible, optimized molding pits or boxes are used for the casting. This process step has an early infl uence on the quality of the fi nished casting, and therefore requires high precision. Questions involving the best pouring position and the arrangement of the foundry cores have to be answered at this time. Last but not least the order and geometry of the casting sprues determine how the molten iron fl ows into the pattern, how it is being distributed and fi nally, how it cools. Nodular graphite cast iron: competence with international standing Let us now focus on the material and process and with it on our core competence, which is casting with nodular graphite cast iron. As one of the world’s biggest hand-molding foundries, Siempelkamp has specialized in the casting of large structural components made of cast iron with nodular graphite. Our casters have the specifi c metallurgic know-how to set the optimal conditions for the solidifi cation process during crystallization of the matrix and the graphite nodules even for thick-walled components. There are only a few foundries in the world that have this specifi c knowledge! Some of our castings have been true records.
The melting process starts with the melting of pig iron and steel scrap in a certain proportion along with additives. Adding magnesium to the molten mass results in the carbon to solidify as spherulite. Embedded into the ferritic matrix, this composition has many good properties: high tensile strength stable yield stress good elongation after fracture good deformability optimal damping features good fatigue strength Compared to steel, the castings made of this material have minimal shrinkage as they cool. Therefore, the familiar defects in steel castings caused by material shrinkage during the cooling process can be largely avoided. This is a tremendous advantage especially for component parts that are highly stressed in selective areas! Since the castings are near the fi nish shape when leaving the mold and typically exhibit a ferritic matrix, casting with nodular graphite cast iron saves time during mechanical machining and imposes minimal wear to tools. Furthermore, casting with nodular graphite cast iron opens up considerable advantages in regard to effi ciency for our customers. Since no heat treatment is necessary, we cut down on one entire production step and save energy. For castings with a weight of up to 300 t (331 US tons) this means considerable savings! Due to the fact that we have special know-how in the composition (metallurgy) of the molten metal, we have a high demand for parts with piece weights of over 150 t (165 US tons). The area of castings with wall thicknesses above 200 mm (7.9 in) requires special knowledge because of the involved slow cooling process. Once the product has solidifi ed and has been removed from the mold, the quality chain continues in the fettling shop. Sand build-ups and fl ashes are removed and our inspectors perform non-destructive testing by means of ultrasound to fi nd out whether defects inside the material exist. Metallographic testing examines cuts under a microscope and assesses the product quality via the microstructure. If desired by the customer, the next step is the machining of the casting. This step is carried out for approx. 30% of our projects. Finally, the castings are shipped to their destinations. Siempelkamp Casting technology Foundry Pouring ladle during deslagging Diesel engine block in fettling shop 74 75
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2009
Page 3 and 4:
4 Foreword 6 Business development i
Page 5 and 6:
The company fi gures for 2009 confi
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Siempelkamp, Krefeld, Germany Total
Page 9 and 10:
A 250 t (276 US tons) upper bolster
Page 11 and 12:
Our development of talented people
Page 13 and 14:
Thin MDF line in Turkey The demand
Page 15 and 16:
Metal forming - market development
Page 17 and 18:
Positioning in the market Compared
Page 19 and 20:
Sales trend The sales volume for th
Page 21 and 22:
Siempelkamp and plants
Page 23 and 24: Siempelkamp Machinery and plants Wo
Page 25 and 26: A new service we are offering is th
Page 27 and 28: We offer innovative products in the
Page 29 and 30: Glue blending is undoubtedly an ext
Page 31 and 32: conditions. By using recycled mater
Page 33 and 34: 32 33
Page 35 and 36: ContiRoll ® technology: continuous
Page 37 and 38: The small 4’ model is especially
Page 39: Short-cycle presses - versatile and
Page 42 and 43: Formation or on of jumbo stac stack
Page 44 and 45: Automation and control technology 2
Page 46 and 47: Industrial automation: 23 accepted
Page 48 and 49: Metal forming Siempelkamp presses f
Page 50 and 51: Open-die forging Open-die forging p
Page 52 and 53: Siempelkamp open-die forging presse
Page 54 and 55: Clutch-controlled screw presses are
Page 56 and 57: p g Side member press for KLT Autom
Page 58 and 59: Our straightening presses process h
Page 60 and 61: FEM M calculation ul Our own foundr
Page 62 and 63: Plants for the rubber industry In 1
Page 64 and 65: Service Effective post-sales servic
Page 66 and 67: A dryer is upgraded Another success
Page 68 and 69: Handling & Automation Within the Si
Page 70 and 71: World record casting Casting
Page 72 and 73: Siempelkamp Foundry: iron casting o
Page 76 and 77: From energy conversion to press con
Page 78 and 79: Pouring u ladle adle during deslagg
Page 80 and 81: Refueling machine Nuclear
Page 82 and 83: Siempelkamp Nuclear Technology: Pro
Page 84 and 85: Engineering solutions from one sour
Page 86 and 87: quality monitoring during productio
Page 88 and 89: Stud ud tensioning sioning machine
Page 90 and 91: Sealing of the drums For the safe a
Page 92 and 93: Konrad container Casks and containe
Page 94 and 95: Gantry an crane ane in control zzon
Page 96 and 97: Diagnostic and monitoring systems:
Page 98 and 99: Services: ageing management for saf
Page 100 and 101: Oil-Offshore platform - steel scrap
Page 102 and 103: Imprint Publisher Executive Editor
Page 104: www.siempelkamp.com 07.10/3500E
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Annual report 2009 - Siempelkamp

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