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GROUND-BREAKING FORMING SOLUTIONS
FOR THE AEROSPACE INDUSTRIES
FORMINGAerospAce
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FORMING THE FUTURE
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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.
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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
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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.
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FORMING THE FUTURE
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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.
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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
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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.
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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
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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.
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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
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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
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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.
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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
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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.
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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.
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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