ulus · pdf file•in-house transfer and progressive stamping die manufacture & design...

ULUS METAL

• 1970 Production of stamped metal parts for automotive industry.

• 2007 Start of production in Gebze plant

• 2009 First non-automotive business started (cooling compressor components)

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Ulus Metal

History

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Ulus Metal

Worldwide Customer PortfolioZF SACHSTurkey, Germany, Slovakia, Spain

TENNECO AUTOMOTIVE Spain, Belgium

THYSSENKRUPP BILSTEINGermany, Romania, USA

MAYSAN MANDO Turkey

• KYB Suspension Europe S.A. Spain

• ISUZUTurkey

• MAGNETI MARELLI Poland

AL-KOSpain

KONI Holland

RECORD France

GABRIEL Europe France

BWI (DELPHI) Poland

WABCOGermany, Poland

•Knorr Bremse –Hasse&Wrede Germany

EMERSON Climate Technologies Northern Ireland, Czech Republic, USA, Belgium

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capsBracket assemblies

Spring seats

Stabbar brackets

Rolled rings

Truck and LCV Chassis brackets

Shock absorber parts Eyering assemblies

Locator brackets

Washers

Holders

Ulus Metal

Overview Product Families

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Cooling Compressor ComponentsBrake System Components

Ulus Metal

Overview Product Families

Machined Parts

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Ulus Metal

Main OEM automotive projects 1/2Fiat Doblo & New Doblo 263 & Fiat Palio & Fiat Albea (ZF Sachs Turkey)Fiat 330 (Fiat Idea&Lancia&Grande Punto)(ZF Sachs Slovakia)

Alfa 955 (Mito) , Alfa 940(ZF Sachs Slovakia)

KIA ED (Ceed) (ZF Sachs Slovakia)

Renault Clio Symbol (Maysan Mando Turkey)Renault L38 / Fluence (ZF Sachs Turkey)

NPR Trucks and NKR Light Duty Trucks Buses(Isuzu Turkey) Supplier for chassis parts.

Volvo (ZF Sachs Slovakia)

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Ulus Metal

Main OEM automotive projects 2/2

Ford Transit V184/V347 , Ford Connect V227(ZF Sachs Turkey)New Transit V36X

Hyundai FD (ZF Sachs Turkey)Hyundai MC (Maysan Mando Turkey)

5 Series (ThyssenKrupp Bilstein Romania)

W212 (ZF Sachs Schweinfurt)BR172 SLK (Tenneco Hannover)911 (Thyssen Krupp Bilstein Germany)%100 supplier for chassis washer.

Axle (Tenneco Belgium)

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Ulus Metal

Core Competencies

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•In-house transfer and progressive stamping die manufacture & design

•Production flexibility for AM and OEM Projects(500 pcs/year up to Million pcs/year)

•Fast prototype manufacture

•Reverse Engineering

•Control gage manufacture

•Hydraulic press forming for deep drawn parts

•Spot welding & Mag welding

•CNC turning and vertical milling

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Ulus Metal

Core Competencies

Reverse Engineering for AM Projects

With CMM machine scanning technology Ulus Metal R&D departmenthas ability to designs parts without 3D drawings.

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Ulus Metal

Core Competencies

R&D – DESIGN and PRODUCTION

For new technologies R&D department with Toolshop makes designs and tests on UnigraphicsNX.

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Ulus Metal

Toolshop

CAD systems :Siemens NX, Mastercam, EzCam

Capabilities :Wire EDMCNC vertical machiningCNC turningSurface grindingConventional turning andmilling machines

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Automated lines (600t-250t)

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Ulus Metal

Production Shopfloor

• Mainly for high volume projects

• Transfer arms (X-Y-Z axis) Deeper part production

• 600 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

Progressive line• Progressive tools for higher

volume parts • Tool capability of

on one shot 1 – 2 or 4 parts production

• 250 Tons• 300 Tons• 350 Tons• 400 Tons

Ulus Metal

Production Shopfloor

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•Progressive tool design andmanufacture

Movie: Inner BracketSteel band view of stabiliser bracket

Progressive tool for stabiliser bracket

Ulus Metal Production Shopfloor –Progressive Press

Ulus Metal

Production Shopfloor

Hydraulic press forming

• Hydraulic Presses for deeper parts

• 250 Tons x2 • 400 Tons

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Ulus Metal Production ShopfloorHydraulic Press - Deep Drawing

•Hydraulic presses withHydraulic hole punchingmahcines

•1x400 Tons / 2 x 250 tons HydraulicPress

Manual tandem stamping(400t-60t)

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Ulus Metal

Production Shopfloor

• Wide range of presses for less volume productions

• From 60 Tons to 400 Tons

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Ulus Metal

Production Shopfloor - CNC Machining

•100% parameter controled Cloos WeldingMachines•500A welding power source•Servo controlled rotating movement torch•MAG welding on upper mount assemblies

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Ulus Metal

Production Shopfloor - Mag Welding

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Ulus Metal

Production - Projection Welding

•Projection welding – inner&outerknuckle brackets, hose holders, abs cable holders

•Welding tools manufactured in-house

•Welding power 300-400-600 kVA

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Poka Yoke System for Renault Bracket Assy

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Ulus Metal

Measurement Capabilities

Laboratory capabilities

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

•Shadow projector device

•Pull-out test device (5t capacity)

•Flatness measurement device

•All kinds of measurement devices; calipers, indicators, height gages, controlgages

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Ulus Metal

Investments

Investments

•600 tons and 400 Tons Transfer Press(Delivery in April 2012)

•CNC Turning Machine(Delivery in July 2011)

•Investment Plan for 2011 – 2012

•800 tons Hydraulic Press

•CNC Milling Machine

•Welding Machine with robot arms

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Ulus Metal

Quality system certifications

Certified by SGS for

• ISO TS 16949 ISO 9001: 2008 ISO 14001 OHSAS 18001

Ulus Metal

Recall Insurance

•Insurance covers, recall and product liability forall our products

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Ulus Metal

Organization Chart

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Thank you for your attention…

ULUS METAL