EXHIBITIONS
DILLINGER/SIEMPELKAMP
(Above and right) In addition to the necessary crane capacities, capable of lifting 480 tonnes, Siempelkamp also has an extensive range of large-format CNC machines, including two gantry-type machining centres.
design, FEM calculation, foundry and production engineers at Siempelkamp. A the end of this process, not only the structure and dimensions of the press, but also the forces necessary for the specific application and therefore the power requirement of the press, are defined. After the completion of planning and calculation, the design department forwards the project to the pattern-making team. “A pattern like this soon takes on the scale of a small single-family house”, Christoph Schmitz notes. Impressions are taken of the finished wooden pattern using quartz sand, and the casting then made. For this 500 meganewton press, a total of twenty-six large components were successively cast in ductile cast iron at Siempelkamp’s Krefeld foundry. As a global specialist in this technology, Siempelkamp was able to assure optimum achievement of the complex geometries needed - as flexurally stiff as necessary, but with thinnest possible structural
thicknesses at less heavily stressed points. The two lower beams, at 287 tonnes finished weight each, were the heaviest contenders. Casting of them, using 320 tonnes of molten iron delivered in five teeming ladles, brought Siempelkamp a new world record. Almost “routine” for the foundry, on the other hand, were the middleweight components for the Nanshan press, such as the two foundation stools, each of 80 tonnes finished weight. Set against this, the four locking supports, each of ‘only’ eight tonnes finished weight, could almost be regarded as “flyweights”. Large castings, such as those for the press for Nanshan, need around four weeks to cool in the sand pit after casting.
Heavy plate
puts on the pressure For the following large-scale machining operation, the components were taken to the machining shop only 400 metres away on the same site on a
heavy-duty multi-axle trailer. In addition to the necessary crane capacities, which are capable of lifting 480 tonnes, they were also met here by an extensive range of large- format CNC machines, including a gantry-type machining centre. Siempelkamp is to deliver the 500 meganewton press as a complete all-in unit, and the entire automation, hydraulic and control systems are therefore also assembled in Krefeld. This assures not only perfect interaction of the individual components with one another, but also trouble-free installation on the
site in China. Nanshan has set demanding specifications: a 280 tonne component may not exceed a tolerance of 10 millimetres, even under exposure to heat. The 2,500 reciprocating tonnes of the moving beam are driven by eight hydraulic cylinders, each of them exerting a press force of 6,250 tonnes. Four retraction cylinders, which are designed to achieve precisely the specified eccentricity and lift the moving beam, are necessary to apply the 50,000 tonnes as uniformly as possible to the customer’s forming die of 1,000 millimetres diameter.
(Left & right) The cylinders completed at Siempelkamp after large-format machining, each with a press force of 6,250 tonnes, are shipped to China by sea. 26 IMT December 2018
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© Siempelkamp
© Siempelkamp
© Siempelkamp
© Siempelkamp
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