aerospace broschuere e

7/30/2019 Aerospace Broschuere e

1/20

GROUND-BREAKING FORMING SOLUTIONS

FOR THE AEROSPACE INDUSTRIES

FORMINGAerospAce


2/20

2

FORMING THE FUTURE


3/20

3

FORMING aeROspace

1903: Th Wight bth tak ff.

On the morning of 17 December 1903,

Orville Wright successfully completed the

first sustained and controlled motorized

flight in the Flyer. He remained aloft

for 12 seconds, and covered a distance

of 37 m (10.8 km/h). The aircraft had a

wingspan of 12.3 m, a length of 6.4 m and

its height measured 2.8 m. It was built

from wood with fabric stretched over

the framework, and its flying weight was

340 kg. The Wright brothers took off andlanded a total of four times on that day.

1900: shul launh thnlgy.

Schuler founded in 1839 began to

extend its production portfolio in 1900

to include eccentric presses and friction

screw presses (developed by Mller

Weingarten, today Schuler). These typesof machines form the basis for the

companys success story in the aerospace

arena. Today, Schuler has a worldwide

presence as a technological leader in

forming technology and offers turnkey

system solutions for the costefficient

production of aviation and space compo

nents light and stable parts made from

the most modern, highperformance

materials.


4/20

4

FORMING THE FUTURE

ALTITUDE 11,000 M, -50 C, MACH 0.85

AND YOU CAN RELAX AND WATCH YOURFILM

Schuler Aerospace. Innovative forming technologies for tomorrows

aircrafts.

The need for mobility in the global village

is growing. Air travel is projected to grow

at annual rates of five percent over the

next two decades. This means global air

traffic will have doubled within 20 years.

The future of flying has just begun.

Schuler is providing the leading future

technology for this market. We are expert

partners for the aviation industry with

groundbreaking concepts and innova

tive forming technologies. Wherever

the highest quality and safest process

technology are called for, wherever

precision, durability, load capacity and

uncompromisingly reliable components

are in demand you will find machines

from Schuler at work.

Now, we are taking the next step by

creating the technological partnership

of Schuler and FormTech. The global

innovation leader in forming technology

is cooperating with the aerospace mar

kets highly regarded experts in titanium

forming. Together, we are developing

solutions to meet new challenges in

terms of technology, safety, environ

mental protection and sustainable use

of resources. Schuler has a partner at

its side which has the highest level of

expertise and knowledge in forming tita

nium alloys the material which will play

an increasingly significant role in future

aircraft production.

Schuler is standing for 170 years of

experience. We are a leader because we

always take one more step providing

the most convincing and innovative solutions for the market.

Jochen Frh, Head of the Forging

technology field, Managing Director of

Schuler Pressen GmbH

Dr. Markus Ernst, member of the Board

of Management of Schuler AG

Arnd Kulaczewski, deputy head of the

Forging technology field, Managing

Director of Schuler SMG GmbH & Co. KG

4


5/20

FORMING aeROspace

FACTS AND FIGURES

Aerospace, SCHULER

Schuler: more than 40 yearsof leading expertise in aerospace forming

technologies.

More than900 Schuler Serviceemployees are at work worldwide around

the clock if necessary.

Factor3Composite aircrafts contain up to 3 times as much

titanium as conventionally designed aircrafts.

105 % growth: current forecast expansionin aircraft fleets until 2030.

Conventional design Composite design

5

50 %

Composites

15 20 %Aluminum

70 %

Aluminum7 %

6 %

7 %

15 20 %Titanium

10 %

5 %9 %Steel

VariousVarious

Steel

CFRP

Titanium

19,000

39,000

2010 2030

Aircraft fleets

This means at least 30,000new deliveries, since airlines will need to replace

retiring aircrafts and as well add new units.


6/20

FORMING THE FUTURE

6


7/20

7

FORMING aeROspace

As Schulers partner for process technol

ogy, FormTech is bringing its outstanding

titanium forming expertise into the alli

ance. FormTech has the highest level ofexpertise in forming processes, materi

als, die design and component develop

ment as well as prototype manufactur

ing. Schulers system manufacturing

expertise and global service will make

these innovative developments available

as reliable forming systems ready for

mass production.

The alliance creates the opportunity for

new approaches to use lightweight and

high performance materials in aircraft

production. As a result, aircraft design

can be optimized with sustainable solu

tions. Fuel consumption and cost per

seat and kilometer flown can be further

reduced as technology advances.

The titanium forming technology de

veloped by Schuler and FormTech now

allows to fully utilize the benefits ofthis material for an extremely wide

range of parts, with only very small

material losses: Hot forming of titanium

panels and plates is a manufacturing

process with an efficient use of resourcesand an enormous reduction in produc

tion costs. For the first time, there is an

economic way of further incorporating

high strength titanium alloys into aircraft

design. The results are lighter designs

with outstanding characteristics opening

up totally new perspectives due to their

cost benefits.

SCHULER AND FORMTECH

TITANIUM FORMING ALLIANCEA groundbreaking technological alliance.

Producing higherperformance components economically.

The technological partner

ship between Schuler and

FormTech allows the cost

efficient use of titanium

alloys for a wide range of

components.

Werner Beck, Managing Director ofFormTech

FormTech has more than 20 years of experience in the development and production of titanium components for

aircraft applications. Today, the portfolio also includes production of sheet metal components made from titanium,

aluminum, nickel and steel materials for many industrial areas. The company is a partner in various international

development projects on new materials and applications such as noise reduction, laminarization of turbulent wing

flow dynamics and optimization of hybrid components. FormTech has leading expertise in superplastic forming.


8/20

8

FORMING THE FUTURE


9/20

9

FORMING aeROspace

pRess TecHNOLOGY FROM

scHULeR

Leading expertise from FormTech com

bined with the mass production skills

of Schuler represent the first step into

a new era of aircraft component pro

duction. Schulers global experience in

manufacturing plant construction will

support titanium forming to take place

in a reliable process with high perfor

mance and efficiency. The technological

foundation for this has been proven in

many applications such as mass produc

tion in the automotive industry or forging

of highstressed components. The new

processes from FormTech are directly

based on this successful experience; as

a result, the new and groundbreaking

solutions for hot forging presses in tita

nium forming not only offer economicalproduction from the beginning, but also

remain reliable over the long haul.

NeW GeNeRaTION OF HOT pResses

The new hot presses from the alliance of

Schuler and FormTech are designed for

unparalleled service life. Newly devel

oped heating and insulation elements

guarantee even heat distribution and high

surface quality due to particlefree pro

duction, as well as a reduction of energy

consumption. The low external tempera

ture reduces stress on machine elements

and increases operator safety. High

quality construction of all press compo

nents with a precise press force profile

plus finely adjustable speed and precise

guide systems increases component

quality, guarantees high reproducibility

and extends die service life. As an option,

the automated part loading, preparation

for hot die changes and production data

acquisition allow for a further increase inproductivity.

aeROspace INDUsTRY

During configuration of the manufactur

ing systems, special attention is paid

to the requirements of the aviation and

space industry. Specific requirements

such as small batch sizes, typical cycle

times for titanium forming and high qual

ity requirements in terms of temperature

tolerance or surface quality can be met

without compromise.

eFFIcIeNT pRODUcTION

Machines from Schuler allow for the

costefficient production of sheet metal

components using the following pro

cesses:. Gas pressure forming (SPF). Diffusion bonding (DB). Hot forming/calibrating.

Hot deep drawing

As a response to growing quantities and part sizes, presses from Schuler permit the cost-efficient production of

components made from titanium, aluminum, nickel and steel at high temperatures.

SPF manufacturing cell Isothermal forging press


10/20

10

FORMING THE FUTURE

FUNcTIONaLITY

Titanium is an outstanding material in

terms of its specific strength. Highest

rigidity of shape can be achieved by em

bossing; sandwich technology allows for

high stiffness against denting even with

thin panels.

WeIGHT ReDUcTION

High performance with reduced weight

new technology for titanium alloys is also

leading to changes in automobile design.

By using titanium, it is possible to significantly reduce the weight of unsprung

masses such as shield plates for a disk

brake and parts that are exposed to high

temperatures such as exhaust compo

nents.

eFFIcIeNcY

Significant advantages in terms of cost

and productivity can be achieved by hot

forming of titanium sheets. For example,

the buytofly ratio of the valuable

raw material titanium is significantly

improved by sheet metal forming as

opposed to milling from solid blocks.

Manufacturing complex part geometries

in one forming step reduces the costs of

material, logistics and installation and

reduces production time compared to

assembly procedures involving severalindividual parts. For example, notable

cost and time savings can be achieved

by superplastic forming of hemispheres

for roll control tanks, which are currently

used in European space rockets during

the launch and ascent phase.

HIGH-TeMpeRaTURe sTReNGTH

aND saFeTY

The hightemperature strength of titani

um allows it to be used in areas exposed

to extreme heat, such as the jet engine

exhaust area, hot gas pipes and pressure

and fireresistant housings. Titanium is

also almost unbeatable when it comes

to safety; for example, its resistance to

hydrazine even enables it to be used

in rocket propellent tanks. Its galvanic

compatibility with composite material

(CFRP) makes it an essential factor inhybrid constructions.

Sheet Metal Part Door Surrounding

Ti 64, Hot Deep Drawing

Tie Rod

Ti 6-4, SPF

Exhaust Plug Segment

TiAl or Ti 6-2-4-2, SPF

Cooler Outlet Duct

Ti 6-4, SPF-DB

Hot forming of titanium alloys is the current hot topic of cost-reduction by preserving the limited titanium ressources and reducing the

production times. Complex sheet metal and tubular parts can be produced by hot gas pressure forming with reasonable die costs.

SPF/DB parts are used for the production of integrally stiffened sandwich-like panels such as hot gas lines, bulkheads, firewalls, hollow

blades and stators used in the engine, etc. Savings can be achieved by a higher level of component integration, reduced number of pro-

duction steps and a cost-efficient manufacturing process.


11/20

11

FORMING aeROspace

AIRPLANE COMPONENTS

Formed titanium parts. The future of aircraft manufacturing

made on Schuler machines.

Bleed air duct system

Pylon brackets

Thrust fittings

Pylon: several parts

Slat track can

Trailing edge: pintle fittings

Nacelles: skins,attachments, attachment ring,

forward bulkhead

Edge angles rear pressure bulkhead

End cap APU

Sheet

Forged

Landing gear: several parts

Scuff platesFlap track: roller track

Engine:

- Fan Blades

- Compressor Blades

- Disks & Rings


12/20

12

FORMING THE FUTURE


13/20

FORMING aeROspace

13

LEADING THE FUTURE

OF FORGINGFrom the screw press to the automated forging cell.

Around the world, light and stable com

ponents made from highperformance

materials are manufactured on Schuler

machines in the hightech area of

aerospace engineering. For example,compressor blades have been forged on

screw presses from Schuler (formerly

Mller Weingarten) for more than 40

years now an unparalleled success

story in the aerospace market.

LOOKING TO THe FUTURe

Schulers market success is based upon

our outstanding innovative potential as a

technological leader. Our investments in

research and development become com

mercial advances in performance and

optimization of entire process systems.

To achieve this, we use various meth

ods such as intelligent automation, new

forming processes and innovative servo

drive technology. The advantages for

our customers are greater flexibility and

increased efficiency.

The new Schuler forging cell

is a significant milestone on

the way to greater flexibility

and efficiency.

Jochen Frh, Head of the Forging

technology field, Managing Director of

Schuler Pressen GmbH

Schuler is present worldwide and is found wherever forging

systems are in use. This claim is supported by 5,000 employees

at sites in Europe, the USA, Mexico, Brazil, India, China and

Russia.


14/20

14

FORMING THE FUTURE

Fan blades

Compressor blades and disks

Compressor Blade (Titanium),

forged on a screw press

Compressor Blade (Titanium), made on

a hydraulic isothermal forging press

Vane (Steel), forged on a

screw press


15/20

15

FORMING aeROspace

THINKING aHeaD

Schuler is a manufacturing system

supplier providing innovative technology,

quality and customeroriented perfor

mance. We aim to be one step ahead of

the competition. Another milestone has

been reached with the development of

Schulers new automated forging cell.

We have been testing this in cooperation

with the renowned Advanced Forming

Research Center (AFRC) at its headquar

ters in Glasgow, Scotland since 2011.

This research center is responsible forsignificant innovations in the aerospace

industry, often with the support of

wellknown manufacturers such as

RollsRoyce, Boeing or Mettis.

The core of our joint project is a direct

drive 2,600 tonne screw press which we

have equipped with the latest drive

technology. In this effort, we are taking

new approaches to produce compressor

blades.

sHapING DeVeLOpMeNTs

Another highlight of the forging cell is

the new bidirectional forging press

from Schuler. It is used for developing

the preforms of compressor blades. By

using highperformance servomotors,

it is possible to program highly diverse

speed profiles and stroke sequences.

Cooperation with AFRC offers Schuler

the ideal conditions for testing new

processes and safeguarding the com

panys leadership position. Our goal isto achieve even greater flexibility in the

forming process in order to offer our

customers the best technology for series

production of an extremely wide range

of materials.

The Advanced Forming Research Center is an institution linked

to the Scottish University of Strathclyde and is concerned with

fundamental research and applied developments in the areas of

forming and forging. The University of Strathclyde was founded in

Glasgow in 1796. Its five faculties currently educate about 22,000

students, mostly in technical subjects. Interdisciplinary work

represents an important focus of teaching and research as a way

of breaking down the traditional limits between disciplines.

The bi-directional forging pressmanufactures preforms for compressor

blades.

Counterblow hammer Hydraulic forging press Screw press


16/20

16

FORMING THE FUTURE

More than 900 Schuler Service employees are working for our customers all over the world around the clock.

They provide assistance in system start-up as well as maintenance and servicing.

HIGHER PERFORMANCE WITH GLOBAL

SERVICE: SCHULERFive building blocks for success. Schuler Service is focused on

productivity, safety, expertise, partnership and the future.


17/20

17

FORMING aeROspace

KeepING YOUR MacHINe IN

TIp-TOp cONDITION

Schuler stands for outstanding perfor

mance and the highest quality. We set

the same goal for ourselves in service,

too. The five building blocks of produc

tivity, safety, expertise, partnership and

future mean that our unique service

offering is precisely tailored to our cus

tomers needs.

Our individually configurable service

packages and productspecific expertise

benefit our customers, with more than

900 highly qualified service employees

worldwide ready to ensure that your pro

duction runs smoothly from the begin

ning. In the final analysis this adds up to

productivity, maximum availability and

safety throughout the entire service life

of your system.

Productivity

Safety

Expertise

Partnership

Future

THe LOcaL GLOBaL pLaYeR


18/20

18

FORMING THE FUTURE

FORMING THE FUTURE

A company with a broad base. In important fundamental markets,

Schuler offers leading technology and convincing quality.

Schuler, the global player, is actively

shaping the future. We have been in themarket for more than 170 years and

have enjoyed success due to our uncom

promising focus on quality and innova

tion. As a global leader of innovative

forming technologies, we offer efficient

and economic solutions: equipment,

production lines, dies, process expertise

and tailormade service for the entire

metal forming industry.

We concentrate on the specific requirements of manufacturers

in their market environment. This is why we focus on definedstrategic market segments. By doing so, we convert technological

leadership into specific customer benefits. This is a clear signal

to our customers: we want to seize the opportunities presented

by technology and grow with you.


19/20

19

FORMING aeROspace

Our customers include automotive

manufacturers and suppliers as well ascompanies from the aerospace indus

tries, domestic goods, forging, energy

and electrical industries. In addition,

Schuler is a leader in the area of minting

technology.

With more than 5000 employees at sites

and agencies in forty countries, we are

present for you almost anywhere in the

world.

For years now, we have played a pioneering role in the industry

when it comes to blue-chip technology and innovation. For this

reason, we bundle our expertise in technology fields. As a result,we maintain our leading market position and our leadership in

innovation for forming technology. We do this with progressive

technology and innovation management, combined with continuous

product development.


20/20

d i d

7 5 0 E 0 7 2 0 1 2 W S P 1 0 0 0 C

i h t b

S h

l

shul pn GmbH (Sales Forging)

Werk Weingarten Schussenstrae 11 88250 Weingarten Germany

Phone + 49 751 4012211 Fax + 49 751 401952211

shul sMG GmbH & c. KG (Sales Hydraulic Press Technologies)

LouisSchulerStrae 1 68753 Waghusel Germany

Phone + 49 7254 988563 Fax + 49 7254 988339

[email protected] /aerospace

aerospace broschuere e

Documents