TPT March 2010

I ndustry N ews

Siempelkamp modernises large closed-die forging press

SIEMPELKAMP, Germany, has been commissioned by Alcoa Forging & Extrusions to engineer and produce the cast parts of one of the world’s largest closed- die forging presses, located in Cleveland, Ohio, USA. Siempelkamp was contracted by Alcoa to help rebuild and modernise its 50,000-ton (450MN) press. The scope of supply consists of 14 large cast parts for the upper, moving and lower beams, as well as the foundation stools. Ten of these castings weigh between 200 and 250tons, and Siempelkamp will cast these structural parts in its own foundry in Krefeld. The closed-die forging press produces structural parts made of aluminium for the aircraft industry. Because of its large press force and its central meaning for the American aircraft industry, the giant press has become a National Historic Mechanical Engineering Landmark in the USA. Within the framework of the order, Siempelkamp has analysed the design from the 1950s, carried out calculations according to the finite-element method, and optimised the construction according to the latest technology and a given maximum component part weight. The result is parts that are fatigue endurable.

The special challenge for the designing engineers was that the new parts, which incorporate 50 years of technological development, had to be exactly in accordance with the old parts, because they simply replace the old parts. Alcoa will carry out the installation of the cast parts on-site.This means that all parts have to fit into the existing press upon arrival. Siempelkamp cast the first foundation stool in August 2009. The beams and stools are machined on large-scale machines capable of processing components with a clamping length of 22m at the Krefeld factory. The combination of engineering, casting, and machining from one source allows Siempelkamp to directly influence the design, due dates, and quality of the components. In May 2009 Siempelkamp made a casting of cast iron with nodular graphite (nodular cast iron) in its Krefeld foundry with a weight of 270tons – to date the heaviest nodular graphite iron casting in the world. Siempelkamp GmbH & Co KG – Germany Fax: +49 2151 92 5683 Website: www.siempelkamp.com

The modernised press will become one of the world’s most advanced and productive forging presses

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