Welcome t o
description
Transcript of Welcome t o
Welcometo
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FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT.
FÉMALK plc
Aluminium HPDC FoundryÖntöde u.10
H-1211 Budapest
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
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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
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°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
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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
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cm
/s, m
m/s
550
570
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610
630
650
670
690
Cel
siu
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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!