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Ulus Metal

9-Apr-14

History :

• 1970 Production of stamped metal parts

for automotive industry

• 2007 Moved to a new plant in Gebze Industrial

zone on a 8000 m2 closed area.

• 2009 First non-automotive business started

• Total Number of employees : 125

• Number of shifts : 1 shift

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Ulus Metal

9-Apr-14

Ulus Metal

Worldwide Customer Portfolio

KYB Suspension Europe S.A.

Spain

TENNECO AUTOMOTIVE

Spain, Belgium, Germany,

Czech, Poland, USA

THYSSENKRUPP BILSTEIN

Germany, Romania, USA

ZF SACHS

Turkey, Germany, Slovakia,

Spain

MAYSAN MANDO

Turkey

ISUZU

Turkey

MAGNETI MARELLI

Poland

WABCO

Germany, Poland, USA,

Brasil, China, India

EMERSON Climate

Technologies

Northern Ireland, Czech

Republic, USA, Belgium,

China

KNORR BREMSE –

Hasse&Wrede Germany

AL-KO

Spain

KONI

Holland, Czech

RECORD France

GABRIEL Europe

France

BWI (DELPHI)

Poland

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Caps Bracket Assemblies

Spring Seats

Stabbar Brackets

Rolled Rings

Truck and LCV Chassis brackets

Shock Absorber Parts

Eyering

Assemblies Washers

Holders

Ulus Metal

Overview Product Families

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Cooling Compressor Components Brake System Components

Ulus Metal

Overview Product Families

Machined Parts

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Ulus Metal

Main OEM automotive projects 1/4

•ZF Sachs – Slovakia

• Fiat 330 Idea & Lancia &

• Grande Punto

Alfa 955 (Mito)

Y413 – XC60

•ZF Sachs - Germany

W212

MFA EVO

• Magneti Marelli

Fiat Fiorino 330

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Ulus Metal

Main OEM automotive projects 2/4

• ZF Sachs - Turkey

Fiat Doblo & New Doblo 263 & Fiat Palio & Fiat Albea

Renault L38 / Fluence

Ford Transit V184/V347 Ford Connect V227

New Transit V36X

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Ulus Metal

Main OEM automotive projects 3/4

• Maysan Mando - Turkey

Hyundai MC Renault Clio

Hyundai IA Symbol

• Tenneco (Monroe) – Germany & Belgium

BR172 SLK

Renault Clio 4 (X98)

Renault Trafic (X82)

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Ulus Metal

Main OEM Automotive projects 4/4

•ThyssenKrupp Bilstein - Romania & Germany

X90 911

NPR Trucks and NKR Light Duty Trucks Buses

Supplier for chassis parts.

• ISUZU - Turkey

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• Experienced Project Management

Team

• In house stamping die design and

manufacturing

• Production flexibility for AM and OEM

Projects

• Fast Prototype sampling

Ulus Metal

Project Management

•Reverse engineering for AM projects

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Ulus Metal

Toolshop

CAD systems :

Siemens NX, Mastercam,

EzCam

Capabilities :

Wire EDM

CNC vertical machining

CNC turning

Surface grinding

Conventional turning and

milling machines

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Transfer lines (600t-250t)

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Ulus Metal

Production Shopfloor

• Mainly for high volume

projects

• Transfer presses with 3D

transfer arms (X-Y-Z axis)

• 600 Tons

• 600 Tons

• 400 Tons

• 350 Tons

• 250 Tons

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•Transfer tool design and manufacture

Movie: Spring Seat Movie: Outer Bracket

Ulus Metal

Production Shopfloor – Transfer Press

9-Apr-14

Progressive lines

• Progressive tools for higher

volume parts

• Tool capability of on one shot

1 – 2 or 4 parts production

• 100 Tons

• 250 Tons

• 300 Tons

• 350 Tons

• 400 Tons

• 500 Tons

Ulus Metal

Production Shopfloor

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•Progressive tool design and

manufacture

Movie: Inner Bracket

Steel band view of stabiliser bracket

Progressive tool for stabiliser bracket

Ulus Metal

Production Shopfloor –Progressive Press

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Ulus Metal

Production Shopfloor

Hydraulic Press - Deep Drawing

• Hydraulic presses with hydraulic hole punching machines

• 600 Tons

• 250 Tons x 2

• 330 Tons

Movie : Production of deep drawn shell (2nd Operation)

Depth : 500 mm

Diameter : 275 mm

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Manual tandem stamping (400t-30t)

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Ulus Metal

Production Shopfloor

• Wide range of presses for less volume productions

• 40 presses from 30 Tons up to 400 Tons 9-Apr-14

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Ulus Metal

Production Shopfloor - CNC Machining

Movie : Production of muffler plate assembly

9-Apr-14

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Ulus Metal

Production Shopfloor

Shock Absorber Body Welding Line • Machines for producing Shock Absorber Body Assembly (Automated Welding Line, welding fixtures, press-fitting presses, leakage test units, punching presses, control fixtures)

9-Apr-14 Movie: Robot Welding of Bracket Assy

•Mag Welding Line

•100% parameter controlled Cloos

Welding Machines

•500A welding power source

•Servo controlled rotating movement

torch

•MAG welding on upper mount

assemblies

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•Spot Welding Line

•Projection welding – inner&outer

knuckle brackets, hose holders,

ABS cable holders

•Welding tools manufactured in-

house

•Welding power 300-400-600 kVA

Ulus Metal

Production - Welding

Poka Yoke System for Renault Bracket Assy 9-Apr-14

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Ulus Metal

Auxiliary Operations

IN-HOUSE :

• Deburring

• Thread cutting

• Riveting

• Chamfering

OUTSOURCED :

• Surface treatment (Zn-Fe coating, Zn-Ni coating, KTL painting)

• Heat Treatment

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Ulus Metal

Raw Materials Used

MATERIAL TYPES

• Hot & Cold Rolled Steel

(DD11, DD12, DD13, S315MC, S355MC, S420MC, DC01, DC03, DC04)

• Profile material for rolled rings

• Stainless Steel

AISI 304 (1.4301)

MATERIAL THICKNESSES

From 0,5 mm up to 6 mm

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Ulus Metal

Measurement Capabilities

Laboratory capabilities • CMM DEA with PCDMIS-CAD ++ software with rotating and scaning probe

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• Shadow projector device • Pull-out test device (5t capacity) • Flatness measurement device • Welding strength test and penetration test devices

CMM Table Size : 1200x1500x1000

CMM Table Size : 2700x1000x6660

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Ulus Metal

Quality system certifications

Certified by SGS for • ISO TS 16949 ISO 9001: 2008 ISO 14001 OHSAS 18001

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Ulus Metal

New Investments

New Investments

• 800 tons Mechanical Transfer Press (Delivery in August)

• CNC Milling Machine

• Spot Welding Machine (750 kVa)

• Coil Feeders

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ULUS METAL

Contact information:

Company Name : Ulus Metal Sanayi ve Ticaret Limited Şirketi

Address : Gebze Organize Sanayi Bölgesi 1000. Sokak No. 1039 Gebze-Kocaeli/ Turkey

Telephone no. : +90 262 677 10 21 – 5 lines

Fax no. : +90 262 677 10 26

Email : info@ulusmetal.com.tr

Web site : www.ulusmetal.com.tr

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Thank you for your attention…

ULUS METAL

9-Apr-14