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Schuler To Deliver Largest Mechanical Forging Presses To Thyssenkrupp

Schuler To Deliver Largest Mechanical Forging Presses To Thyssenkrupp

In 2022, thyssenkrupp Gerlach is expected to start production on a Farina forging press from Schuler. Internal assembly for the 16,000-ton line one of the largest mechanical machines in the world has been completed in Suello, Italy, and after the test run the components with a total weight of 1,700 tons will make their way to the customer’s forging plant in Homburg, Germany.

The Farina GLF series presses cover forces from 750 to 16,000 tons. They feature a novel direct drive concept without connecting rods. Thus, the design engineers at Schuler and Farina succeeded in reducing the machine height compared to conventional presses. One result of the optimisation for hot forging is, among other things, a very high deformation reduction and thus a significantly reduced flash thickness on forging parts.

Farina had already supplied a 4,000-ton forging press to thyssenkrupp in 2008. Schuler had acquired the Italian press manufacturer based in Suello, the leading European supplier of forging lines in the mid-price segment, in 2018.

“This order shows that we have successfully completed our product portfolio with this acquisition,” said Schuler general manager Frank Klingemann.

 

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Thyssenkrupp Orders Farina Forging Press

thyssenkrupp Orders Farina Forging Press

16,000 tons of concentrated press force, 1,700 tons of weight and a height of ten meters: The Farina forging press, which thyssenkrupp Gerlach ordered from Schuler in April 2019, is one of the world’s largest mechanical systems of its kind. Starting in 2021, the GLF 16000 machine will form truck front axles and crankshafts at the Homburg site.

Schuler had taken over the Italian press manufacturer Farina in 2018. It is the leading European supplier of forged lines in the mid-price segment. thyssenkrupp has been so satisfied with a 4,000-ton forging press, which Farina had supplied in 2006, that the company again opted for the GLF series – but this time for a four times more powerful model. Schuler will manufacture the large press at its Erfurt location.

360,000 components per year

“The main press of the new forging line will be the world’s first eccentric press of this size, capacity and output to go into operation,” says Dr. Franz Eckl, COO of the Forged Technologies business unit. “It will produce around 360,000 forged components per year.”

thyssenkrupp has been manufacturing forged components at the Homburg site since 1947. With a roughly 750-strong workforce it is one of the region’s biggest employers. Construction of the world’s most advanced forging line is scheduled to start in early 2020. The roughly 12,000 square meter facility will be built on the existing site, with completion and start of production planned for early 2021.

Chassis Components Powertrain-Independent

The plant has long been one of the most efficient production sites in thyssenkrupp’s global forging network. It is market leader for forged crankshafts, supplying automotive customers worldwide. The production of truck front axles will open up a new market and product segment for the company. These chassis components are powertrain-independent and will continue to be needed even when e-mobility starts to make greater inroads into the transportation sector.

thyssenkrupp’s “Forged Technologies” business unit is now one of the world’s largest forging operations with annual sales in excess of one billion euros. Its product portfolio includes forged and machined components and systems for the automotive, construction machinery and general engineering sectors. thyssenkrupp’s forging business currently employs around 7,500 people.

 

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Global Forging Market To Reach US$96B By 2025

Global Forging Market To Reach US$96B By 2025

The global forging market is expected to register a compound annual growth rate (CAGR) of 4.4 percent between 2017 and 2025 to reach US$96.4 billion by the end of the forecast period, according to a new report by Transparency Market Research.

Mainly driving this growth is the rising application in multiple industries such as construction, wind, aerospace, automotive, and power generation, to name a few. Further driving the growth of the forging market are the high demand for ferrous metals and high-strength metal components, along with cost-effective methods of metal forming. Moreover, use of novel and advanced technologies by key market players is expected to provide a significant push and expand the global forging market.

There are a few challenges seen to deter the growth of the forging market, however. Factors such as the volatile nature of several end-use industries and the expensive high-quality forged steel products are projected to hamper growth in this market. The uncertain partnership between material producers and forging units is also estimated to obstruct growth in this market, so do the increasing environmental concerns, high demand for plastics as a substitute, and growing usage of stamping and casting process. Still, the rapid pace of industrialisation that boosted various industries in emerging economies might help in overcoming these challenges.

Asia Pacific will remain the largest market with impressive growth due to the rapid increase of construction and automotive industries in the region. Furthermore, the huge number of global players in the region also contributes to its growth.

 

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