Create a superior hot forging center

Today, the use of hot forging forming (or thermoforming) car body parts has become more and more common, because many countries around the world have issued more stringent car safety regulations, requiring car manufacturers and their suppliers to adopt lightweight steel structure New manufacturing method.

In early 2008, the Schuler Group brought together its specialists in hot forging processes and equipment, and created a superior hot forging center at its Wagh?usel plant in Germany, in order to provide customers with both mechanical and independent integration. Process consulting. In the newly established Center of Excellence, a number of experts from the aspects of process technology, press structure, molds and automation technology will vigorously promote the large-scale production, application and continuous development of hot forging technology in the automotive industry. At present, the excellent hot forging center will also vigorously promote future-oriented system solutions while considering the development of modern steel products. The development goals of the excellent hot forging center are: to reduce the cycle time, optimize the process, thereby reducing the cost of a single part; in the cooperation with customers and steel manufacturers, constantly improve the quality of parts, so that the system has greater flexibility.

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The development goals of the excellent hot forging center are: to reduce the cycle time, optimize the process, thereby reducing the cost of single parts;
In the cooperation with customers and steel manufacturers, continuously improve the quality of parts and make the system more flexible

Hot forging is a new and highly complex manufacturing process. There are many factors that affect cycle time and part quality. The Schuler Group has successfully installed more than 30 production lines worldwide and has considerable know-how throughout the entire processing chain, from rough stocks to finished products.

Excellent Hot Forging Center

The Excellence Hot Forging Center is managed by experts in process technology and hydraulic machine experts from Schuler SMG. Schuler Automation offers know-how in the fast and safe transmission of parts. Currently, Schuler Automation is installing several hot-forging production lines equipped with Schuler bar robots and newly developed transmission technologies in Europe.

As mold technology plays a key role in hot forging, the mold structure experts at Schuler Cartec are also recruited to the team. Their job is to provide creative solutions that meet the special requirements of cooling molds. Its purpose is to develop simulation software and simplify mold design. In cooperation with the Volkswagen Kassel plant, Schuler Press has developed soft impact technology for cutting high-strength finished parts.

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Figure 1 The part code is placed in the logistics container

Currently, the Schuler Group is developing several hot-forging production lines for a global leading supplier of car parts for the manufacture of various safety components made of high-strength steel. This project involves the group projects of Schuler SMG, Schuler Automation, Schuler Press and Schuler Cartec, and the customer can quickly experience what benefits can be achieved through the internal cooperation of the Schuler Group. Compared with the past, excellent hot forging centers can provide more effective solutions, new automation and press concepts and mold technology are now being used, and parts are made on specially designed mechanical presses equipped with Schuler soft impact technology. Cutting. Before the part is quenched and formed in a hydraulic press, the web needs to be heated to 930°C. In Figure 1, a robot with a special end picker places the still-formed part code in a logistics container. The production of thermoformed parts uses 8 000 kN hydraulic presses. The mold design incorporates an integrated water cooling circuit to control the cooling of the parts during the quenching process, as shown in Figure 2.

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Figure 2 Control Parts Cooling

Press Structure - Strengths of Using Hydraulic Press Technology

The hydraulic machine has a high degree of flexibility and is particularly suitable for hot forging. The correct design of the press is crucial. The combination of forming and cutting-edge mold technology can be individually adjusted to facilitate the reproduction of each part.

Mold Technology - Simulation and Manufacturing

When making hot forging dies, Schuler Cartec offers dies for the entire machining range (from simulation to mass production). This applies both to the actual forming of the mold and to the cutting of high-strength steel parts. The Schuler Group combines the soft impact processes jointly developed by Schuler Press and Volkswagen and takes new steps in this area to implement a process that reduces the stress on the mold. This process costs more than laser cutting. Both quality and quality occupies a great advantage.

Automation Technology - Safe and Fast

Large-scale production of hot forging machines has a fully automated system solution. Therefore, in the following devices, the use of automation plays a decisive role: before and after the heating furnace, the loading and unloading of the hydraulic press, cutting and processing of finished products and high-strength parts. The Schuler Group uses crossbar robots, special transmission equipment and advanced optical part identification devices to provide reliable automation solutions with a high degree of processing flexibility and reliability.

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