Transcript Welcome to FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. FÉMALK plc Aluminium HPDC Foundry Öntöde u.10 H-1211 Budapest [email protected] www.femalk.com Location of the company.

Welcome
to
FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT.
FÉMALK plc
Aluminium HPDC Foundry
Öntöde u.10
H-1211 Budapest
[email protected]
www.femalk.com
2
Location of the company
3
FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry
Öntöde u. 10, H-1211 Budapest
Budapest, Hungary
4
FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry
Öntöde u. 10, H-1211 Budapest
5
FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry
Öntöde u. 10, H-1211 Budapest
4000 m2
9000 m2
6
Important data and
organization of the company
7
Important data
•
•
•
•
•
•
•
•
•
•
Aluminium high-pressure die casting foundry
founded 1989
family owned
25,2 Million € turnover in 2010
38 Million € turnover in 2011
46 Million € turnover in 2012
Of which 100% automotive
500 employees
3 shifts on 5 days
13,000 sqm area
8
Capability
• participation in designing of parts
• testing activates: dynamic and static testing
• designing of dies and machining tools
• building of dies and machining tools
• casting
• machining
• assembly
9
Main process
(Pre-) Development
Tool construction
(Series- and Prototype tool)
Validation testing
Production:
CAD Systems:
Catia V5 R16-19
Pro/E Wildfire 3-4
FEM Systems:
Ansys v12
Catia GPS
Filling simulation:
NovaFlow&Solid
-Casting
-Machining
-Surface treatment
-Assembly
Quality planning, Quality control Quality monitoring
1010
Development and tool
production
11
Parts development
Software:
Pro/Engineer Wildfire 2.0 and 3.0
Catia V5
Possible Access to UGS/NX
12
Direct development for the BMW 1 and 3 series
Transmissions bracket and Transmissions cross member
- Project start end of 2009
- Part development
- FEA calculations
- Sand casting prototype’s
- Mold construction
- SOP 2011 July
13
Direct OEM - New projects in 2012
Gearbox mounts
Fastener
Engine mounts
Gearbox mount
…and further 4
Development
contracts for
totaly 16 parts
BMW i8 - Engine mount , Gearbox cross member
FEA Simulation
ANSYS v12
Linear and bilinear
material properties
Catia GPS
Linear
material properties
16
Cooperation with Universities
• University of Miskolc
Budapest University of Technology
• Aalen University
17
Mould filling and solidification simulation
Software:
Nova Flow& Solid
Form fill-, solidificationand cycle simulation.
•Temperature
•Velocity
•Solidification
18
Mould design
Software
Pro/Engineer
Pro/Engineer Wild
Fire Version 2
Mold design
NC Machining
19
Tool shop
Machining Centre:
Spark erosion machine:
Sodik AQ 55 Deckel-Maho
70V
Starthole drilling machine: Sodik K1C Excel
MC-5V
Wire spark erosion machine: Sodik AQ 35 Dugard Eagle
850
Finetech
SMV-1100
Lywentech Mythron
HSM85A
Lywentech Zeigler
LZ-720
20
Production
21
Types of Aluminium alloys
EN AC 44300
EN AC 46000
EN AC 47100
Silafont 36
EN AC-AlSi12(Fe)
230
EN AC-AlSi9Cu3(Fe) 226
EN AC-AlSi12Cu1(Fe) 231
AlSi9MgMn
Nevertheless we accomplish kindly special
requests of our customers, too.
22
Smelting-shop
Smelting furnace:
Morgan Crucible furnace
Striko Shaft furnace 2000/1000
Hormesa reverberatory furnace SH3.UB-G
Hormesa reverberatory furnace SH3.0F-G
Striko Westofen 4000/2000
500 kg
2000 kg
3000 kg
3000 kg
2000kg
1 pcs.
1 pcs.
1 pcs
1 pcs.
1 pcs.
Smelting and Holding furnaces:
Shaft smelt and holding furnace:
250 kg
5 pcs.
Liquid metal treatment:
Filter furnace
slag-, gas-, salt-, nitrogen treatment
1 pcs.
23
The foundry
Casting cell:
Manual machine:
Locking force:
23 pcs.
1 pcs.
250 - 960 tons
24
Horizontal HPDC machines
Machine
number
Locking force
Machine brand
Cella
1
250
Bühler
Manual machine
2
420
Zitai
Die casting cell
x
3
420
Zitai
Die casting cell
x
4
730
Zitai
Die casting cell
x
6
560
Zitai
Die casting cell
7
650
OMS
Die casting cell
x
8
500
Zitai
Die casting cell
x
9
560
Zitai
Die casting cell
10
400
OMS
Die casting cell
x
11
650
OMS
Die casting cell
x
12
700
Oleopres
Die casting cell
x
13
860
Frech
Die casting cell
x
Robot
25
Horizontal HPDC machines
Machine
number
Locking force
Machine brand
Cella
14
420
Zitai
Die casting cell
15
250
Zitai
Die casting cell
16
560
Zitai
Die casting cell
21
350
Zitai
Die casting cell
22
700
OMS
Die casting cell
x
23
500
OMS
Die casting cell
x
41
400
Weingarten
Die casting cell
x
42
500
Öntögépszervíz
Die casting cell
x
43
800
OMS
Die casting cell
x
44
400
OMS
Die casting cell
x
45
500
Öntögépszervíz
Die casting cell
x
Robot
960 ton Horizontal HPDC Frech casting cell
27
700t DGM casting cell
28
0
2005.08.02. 18:00
2005.08.02. 17:00
2005.08.02. 16:00
2005.08.02. 15:00
2005.08.02. 14:00
2005.08.02. 13:00
2005.08.02. 12:00
2005.08.02. 11:00
2005.08.02. 10:00
2005.08.02. 09:00
2005.08.02. 08:00
2005.08.02. 07:00
2005.08.02. 06:00
°C
Permanent temperature control of
the melting furnaces
Olvasztók hőmérséklete
Temperature
of the smelting furnace
1000
900
800
700
068
600
120
500
166
400
300
092
200
302
100
Hőke
29
Permanent control of the casting parameters
1 7 -s
ö n tő g é p a17
d a ta i
Maschine
2 0 0 5 .0 2 .0 2 . 1 8 :0 0 :2 2 - 2 0 0 5 .0 2 .0 3 . 0 5 :5 9 :2 4
400
690
N a g y s e b e s s é g (c m /s )
350
670
650
250
H ő ta rtó k e m e n c e h ő m é rs é k le te (°C )
630
M u lti n yo m á s (k g f/c m 2 )
200
C e ls iu s
m m , m s , m s , c m /s , m m /s
300
A la c s o n y s e b e s s é g (m m /s )
610
150
N yo m á s fe lfu tá s (m s )
S e b e s s é g fe lfu tá s (m s )
100
P o g á c s a va s ta g s á g (m m )
590
570
50
0
2 0 0 5 . 2 . 2 . 1 8 :0 0
S p e e d _ R is e (m s )
550
2 0 0 5 . 2 . 2 . 2 0 :2 4
IN T _ R is e (m s )
2 0 0 5 . 2 . 2 . 2 2 :4 7
B is c u it T h ic k (m m )
IN T _ P re s s (k g f/c m 2 )
2 0 0 5 . 2 . 3 . 1 :1 1
L o w _ S p e e d (m m /s )
2 0 0 5 . 2 . 3 . 3 :3 5
H ig h _ S p e e d (c m /s )
2 0 0 5 . 2 . 3 . 5 :5 9
H ő ta rtó k e m e n c e (°C )
30
Permanent control of the casting parameters
Immediate error
message if parameters
are incorrect
31
CNC machining-shop
ENSHU JE60 CNC machine
Heckler &Koch BA20 CNC machine
Mori Seiki CNC
Mori Seiki NH400 CNC machine
Mori Seiki SL 1000 CNC lathe
Doosan automatic CNC lathe
Alzmetall CNC drilling- and crew machine
Steinel BS500 multiple-spindle drilling machine
1 pcs
2 pcs
1 pcs
1 pc
1 pcs
1 pcs
1 pcs
1 pcs
32
Surface treatment
Blasting process
Overhead rail shot blasting machine (Schlick)
Inline shot blasting tunnel (Trowal)
Moulder belt shot blasting machine (Tauss)
Deburring process
Trough vibrator (Trowal)
Circular vibrator (Rösler)
33
Assembly
CRIMPING
Developed by FÉMALK !
Specialty: cold forming by 1,5%
elongation of the alloy!
34
Quality assurance system
35
History of our Quality
management system
11.02.2000:
ISO 9002/QS 9000
27.07.2001:
VDA 6.1
30.11.2002:
ISO TS 16949
31.05.2005:
ISO 14001
36
ISO/TS 16949:2002 und ISO 14001
37
Bosch preferred supplier award
2011 and 2012
38
Sándor József
Businessman of the year 2012 by Ernst&Young
Quality control
3D coordinate measuring machines
40
Quality control
Spectrometer
Leak tester equipment
41
Quality control
X-ray
42
Quality control
Microscope
Universal testing machine
43
Products
44
Products for vibration control
trucks
45
Products for vibration control
passenger cars
46
Top Mount for VW Golf, Passat,
Audi A3, Skoda Roomster
47
Top mount for shock absorbers
48
Products for headlights
49
Parts for air condition compressors
50
Products for electronic parts
51
Products for engine
52
Transmission brackets
53
Transmission console
Development of turnover
and customers
55
Turnover development at Fémalk
56
2012 Turnover split
57
2013 Turnover split (Forecast)
58
Locations of our customers
59
Our direct customers
60
OEM’s where finally our products get to
61
Future development
62
New Investments Csepel 2012
Die casting cells with Robot
• 400t – 1pcs OMS
• 650t – 1pcs OMS
• 800t – 1pcs OMS
• 650t – 1pcs OMS
Surface treatment
New tumbling machine
63
Dunavarsány - New Plant
Dunavarsány - New Plant
• Fémalk is planning an additional production
plant in Dunavarsány / 30km from Csepel
• Area: 60.000qm
• Double HPDC capacity
• Possibility to improve / build up CNC
Machining
65
Thank you for your attention!
66