November 2023 Volume 5

EQUIPMENT & TECHNOLOGY

One notable innovation is the utilization of ceramic blocks for thermal insulation of the tools. These ceramic blocks prove highly effective, particularly under the tremendous forging forces. Moreover, this insulation plays a crucial role in safeguarding the press components from excessive heat. (Fig. 2)

Fig.3: Hot Isothermal Forging line (HIF) from SMS group The approach to power management includes the power supply for the furnaces as well as ancillary supply and operating systems, ensuring seamless operation throughout the forging process. To oversee and manage the entire HIF-line, A control and monitoring system is used. This system is integrated into a broader digitalization framework. Additionally, the system is supported by SMS group´s Digitalization Platform, “Management Information Diagnostic Indication System,” enhancing the overall efficiency and reliability of the forging process. Conclusion As a full-line supplier, SMS group introducing the newly developed HIF-line, represents a culmination of the hydraulic closed-die forging, vacuum and furnace technology, and tool expertise. It merges decades of experience in the designing and constructing hydraulic driven closed-die presses for both conventional and hot die forging that will prove a major benefit to the industry. Based on the past several years of experience in the production of turbine parts for the aircraft and aerospace industry with the HIF system, it would be wise for the industry at-large to use this technology for the production of parts for high-temperature power plant turbines. Dr. Serdar Tuncel SMS group Inc., USA Email: serdar.tuncel@sms-group.com Axel Roßbach, SMS group GmbH, Germany Email: axel.rossbach@sms-group.com Cihangir Demirci SMS group GmbH, Germany Email: cihangir.demirci@sms-group.com

Fig.2: Die stack with insulation. The concept of a HIF unit is based on round, multi-vacuum chamber design with the key components illustrated in Fig. 3. 1. Hydraulic closed die forging press 2. Loading and unloading chambers with integrated furnaces for heating of the work pieces 3. Unique charging chamber with integrated manipulator 4. HIF chamber with combined heating furnaces for the upper and lower dies 5. Tool chambers for exchanging of the upper and lower dies 6. Vacuum slide gates 7. Charging chamber with integrated handling cars for upper and lower dies The hydraulic system is characterized by tightly controlled strain rates, which enable precise speed and force control. This system is designed with an energy saving concept in mind and boasts a dynamic behavior system for the hydraulic unit, optimizing overall performance. Heating furnaces are equipped with multiple zone heating elements, allowing for precise temperature control and uniform heating. To ensure the quality of the final product, a monitoring system is implemented for both workpiece and the dies. The vacuum unit with integrated mechanical vacuum pumps and filter systems reaches the required vacuum level for the HIF process.

FIA MAGAZINE | NOVEMBER 2023 15