Welcometo

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FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT.

FÉMALK plc

Aluminium HPDC FoundryÖntöde u.10

H-1211 Budapest

femalk@femalk.hu

www.femalk.com

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Location of the company

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FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC FoundryÖntöde u. 10, H-1211 Budapest

Budapest, Hungary

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FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC FoundryÖntöde u. 10, H-1211 Budapest

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9000 m2

4000 m2

FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC FoundryÖntöde u. 10, H-1211 Budapest

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Important data and organization of the company

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Important data

• Aluminium high-pressure die casting foundry• founded 1989• family owned• 25,2 Million € turnover in 2010• 38 Million € turnover in 2011• 46 Million € turnover in 2012• Of which 100% automotive• 500 employees• 3 shifts on 5 days• 13,000 sqm area

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Capability

• participation in designing of parts

• testing activates: dynamic and static testing

• designing of dies and machining tools

• building of dies and machining tools

• casting

• machining

• assembly

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Main process

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(Pre-) Development

CAD Systems:Catia V5 R16-19Pro/E Wildfire 3-4FEM Systems:Ansys v12Catia GPS

Tool construction (Series- and Prototype tool)

Quality planning, Quality control Quality monitoring

Production:-Casting-Machining-Surface treatment-Assembly

Filling simulation:NovaFlow&Solid

Validation testing

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Development and tool production

1212

Parts development

Software:Pro/Engineer Wildfire 2.0 and 3.0Catia V5Possible Access to UGS/NX

Direct development for the BMW 1 and 3 series

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Transmissions bracket and Transmissions cross member- Project start end of 2009

- Part development- FEA calculations - Sand casting prototype’s

- Mold construction- SOP 2011 July

Direct OEM - New projects in 2012

Gearbox mounts

Fastener Gearbox mount

Engine mounts …and further 4 Development contracts for

totaly 16 parts

BMW i8 - Engine mount , Gearbox cross member

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FEA Simulation

ANSYS v12 Linear and bilinear material properties

Catia GPSLinearmaterial properties

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• University of Miskolc

• Aalen University

Budapest University of Technology

Cooperation with Universities

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Mould filling and solidification simulation

Software:

Nova Flow& Solid

Form fill-, solidification- and cycle simulation.•Temperature•Velocity•Solidification

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Mould design

Software

Pro/EngineerPro/Engineer Wild Fire Version 2Mold designNC Machining

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Spark erosion machine: Sodik AQ 55Starthole drilling machine: Sodik K1CWire spark erosion machine: Sodik AQ 35

Tool shop

Machining Centre: Deckel-Maho 70VExcel MC-5VDugard Eagle 850Finetech SMV-1100Lywentech Mythron HSM85ALywentech Zeigler LZ-720

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Production

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Types of Aluminium alloys

EN AC 44300 EN AC-AlSi12(Fe) 230

EN AC 46000 EN AC-AlSi9Cu3(Fe) 226

EN AC 47100 EN AC-AlSi12Cu1(Fe) 231

Silafont 36 AlSi9MgMn

Nevertheless we accomplish kindly special

requests of our customers, too.

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Smelting-shop

Smelting furnace: Morgan Crucible furnace 500 kg 1 pcs.Striko Shaft furnace 2000/1000 2000 kg 1 pcs.Hormesa reverberatory furnace SH3.UB-G 3000 kg 1 pcsHormesa reverberatory furnace SH3.0F-G 3000 kg 1 pcs.Striko Westofen 4000/2000 2000kg 1 pcs.

Smelting and Holding furnaces:Shaft smelt and holding furnace: 250 kg 5 pcs.

Liquid metal treatment:Filter furnace 1 pcs.slag-, gas-, salt-, nitrogen treatment

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Casting cell: 23 pcs.

Manual machine: 1 pcs.

Locking force: 250 - 960 tons

The foundry

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Horizontal HPDC machines

Machine number Locking force Machine brand Cella Robot

1 250 Bühler Manual machine  

2 420 Zitai Die casting cell x

3 420 Zitai Die casting cell x

4 730 Zitai Die casting cell x

6 560 Zitai Die casting cell  

7 650 OMS Die casting cell x

8 500 Zitai Die casting cell x

9 560 Zitai Die casting cell  

10 400 OMS Die casting cell x

11 650 OMS Die casting cell x

12 700 Oleopres Die casting cell x

13 860 Frech Die casting cell x

Horizontal HPDC machines

Machinenumber Locking force Machine brand Cella Robot

14 420 Zitai Die casting cell  

15 250 Zitai Die casting cell  

16 560 Zitai Die casting cell  

21 350 Zitai Die casting cell  

22 700 OMS Die casting cell x

23 500 OMS Die casting cell x

41 400 Weingarten Die casting cell x

42 500 Öntögépszervíz Die casting cell x

43 800 OMS Die casting cell x

44 400 OMS Die casting cell x

45 500 Öntögépszervíz Die casting cell x

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960 ton Horizontal HPDC Frech casting cell

700t DGM casting cell

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Olvasztók hőmérséklete

0

100

200

300

400

500

600

700

800

900

1000

2005

.08.

02. 0

6:00

2005

.08.

02. 0

7:00

2005

.08.

02. 0

8:00

2005

.08.

02. 0

9:00

2005

.08.

02. 1

0:00

2005

.08.

02. 1

1:00

2005

.08.

02. 1

2:00

2005

.08.

02. 1

3:00

2005

.08.

02. 1

4:00

2005

.08.

02. 1

5:00

2005

.08.

02. 1

6:00

2005

.08.

02. 1

7:00

2005

.08.

02. 1

8:00

°C

068

120

166

092

302

Hőke

Permanent temperature control of the melting furnaces

Temperature of the smelting furnace

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2005.02.02. 18:00:22 - 2005.02.03. 05:59:24

0

50

100

150

200

250

300

350

400

2005. 2. 2. 18:00 2005. 2. 2. 20:24 2005. 2. 2. 22:47 2005. 2. 3. 1:11 2005. 2. 3. 3:35 2005. 2. 3. 5:59

mm

, ms

, ms,

cm

/s, m

m/s

550

570

590

610

630

650

670

690

Cel

siu

s

Speed_Rise (ms) INT_Rise (ms) Biscuit Thick (mm) INT_Press (kgf/cm2) Low_Speed (mm/s) High_Speed (cm/s) Hőtartó kemence (°C)

Nagy sebesség (cm/s)

Alacsony sebesség (mm/s)

Hőtartó kemence hőmérséklete (°C)

Multi nyomás (kgf/cm2)

Nyomás felfutás (ms)

Sebesség felfutás (ms)

Pogácsa vastagság (mm)

17-s öntőgép adataiMaschine 17

Permanent control of the casting parameters

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Permanent control of the casting parameters

Immediate error message if parameters

are incorrect

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ENSHU JE60 CNC machine 1 pcsHeckler &Koch BA20 CNC machine 2 pcsMori Seiki CNC 1 pcsMori Seiki NH400 CNC machine 1 pc

Mori Seiki SL 1000 CNC lathe 1 pcsDoosan automatic CNC lathe 1 pcsAlzmetall CNC drilling- and crew machine 1 pcsSteinel BS500 multiple-spindle drilling machine 1 pcs

CNC machining-shop

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Surface treatment

Blasting process

Overhead rail shot blasting machine (Schlick)Inline shot blasting tunnel (Trowal)Moulder belt shot blasting machine (Tauss)

Deburring process

Trough vibrator (Trowal)Circular vibrator (Rösler)

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Assembly

CRIMPINGDeveloped by FÉMALK !Specialty: cold forming by 1,5%

elongation of the alloy!

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Quality assurance system

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11.02.2000: ISO 9002/QS 9000

27.07.2001: VDA 6.1

30.11.2002: ISO TS 16949

31.05.2005: ISO 14001

History of our Quality management system

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ISO/TS 16949:2002 und ISO 14001

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Bosch preferred supplier award2011 and 2012

Sándor JózsefBusinessman of the year 2012 by Ernst&Young

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Quality control

3D coordinate measuring machines

Quality control

Leak tester equipmentSpectrometer

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X-ray

Quality control

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Quality control

Microscope Universal testing machine

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Products

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Products for vibration controltrucks

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Products for vibration controlpassenger cars

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Top Mount for VW Golf, Passat,Audi A3, Skoda Roomster

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Top mount for shock absorbers

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Products for headlights

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Parts for air condition compressors

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Products for electronic parts

Products for engine

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Transmission brackets

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Transmission console

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Development of turnover and customers

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Turnover development at Fémalk

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2012 Turnover split

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2013 Turnover split (Forecast)

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Locations of our customers

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Our direct customers

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OEM’s where finally our products get to

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Future development

New Investments Csepel 2012

Die casting cells with Robot• 400t – 1pcs OMS• 650t – 1pcs OMS• 800t – 1pcs OMS• 650t – 1pcs OMS

Surface treatmentNew tumbling machine

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Dunavarsány - New Plant

Dunavarsány - New Plant

• Fémalk is planning an additional production plant in Dunavarsány / 30km from Csepel

• Area: 60.000qm

• Double HPDC capacity

• Possibility to improve / build up CNC Machining

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Thank you for your attention!