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Forge Production
2
Business of Autocomponents Division
Chassis and Power Train systems
Steering system
Brake system
Fuel system
Driving and non-driving axles
Suspension modules
Clutch
Wheel discs
Leaf springs
Control systems
Body armature
Stamped parts
Truck beds
Frame
Body
Success factors in detail
Tools and accessories
Dies and press-molds
Fasteners
(JV Bulten-GAZ)
Tooling
Joint ventures
Exhaust system
(JV Bosal-GAZ)
Forge
Iron castings
Aluminum and other
non-ferrous casting
Blanking production
One of the largest Forges in RF
A complete technological cycle of die forging
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GAZ JSC
Space, м2
Master forging Shop 34 755
Forging-Press Shop
46 567 Large hot stampings area (line
12500 tf)
Forging –
Press Shop
Master forging
Shop
Large hot
stampings area
(line 12500 tf)
Location forging production
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Forge parts
Production has a complete technological cycle of forgings manufacture
by die forging (including heat treatment, straightening, coining and
scale removal). Blanks for stamping are heated in induction gas and
electric furnaces, direct resistance heating is also applied. Forgings are
normalized, thermally refined and also are subject to isothermal
annealing
• One of the largest Forges in RF
• 1200 items of forging blanks (forgings, pressed
parts) manufactured from constructional and alloyed
steels, АК6 aluminum alloys
Production capabilities
Customers
Forge parts
Forge Quality Management System has been certified for compliance with
State Standard P ISO 9001-2008
Capacities: 110 thou. tons per annum
Wide range of forging equipment:
• Crank hot-forming presses with tonnage ranging from 630 to 6 300
• Automatic line for stamping large parts (based on forging hot stamping
press with tonnage of 12 500 – 2 pcs
• “HATEBUR” AMP-70 series automatic hot stamping press with tonnage of
1 500 – 1 pcs
• EUMUCO automatic lines with tonnage of 3 150 – 2 pcs
• Automatic transverse v-shaped rolling line WRL10025TN-1, 40 tf – 1 pcs
• Horizontal forging machines with tonnage ranging from 250 to 2 000
• Pneumatic die hammers with driver assemblies weighing 1 000 kg - 5 pcs
• Clamping machines for manufacture of steering wheel shaft and tie rods –
4 pcs
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Forge products
Connecting rod and connecting rod caps weighing
from 0,3 to 2 kg
Front axle beams weighing from 26 to 160 kg
Gears of different overall dimensions weighing from 0,8
19 kg
Levers and forks weighing 0,1 to 5 kg
Shafts weighing from 3 to 7 kg
As well as flanges, T-branches, hooks and other
forgings
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50%
2%
AMZ
Nizhny Novgorod Motors,
Technopark
GAZ
3%
KAAZ
2%
ZZGT
2%
Russian Railways
2%
SAAZ
2% UMZ
Other (URAL, PAZ, YAZDA and etc.)
2%
17%
8%
2%
Cooperation
Automobile Plant GAZ
ZMZ
Rosstar
2%
5%
Customer's portfolio
Development of sales to external
customers (outside GAZ Group)
Factors:
- increase of number of OEM in Russia and
localization of forgings production
- increase of forgings production for different
branches of industry
2013
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Equipment of
GAZ Forging
Production
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Technologies
Complete technological cycle of forging production by hot die forging (including heat
treatment, straightening, embossing and scale removal)
Heating of blanks before pressing blanks is made in induction installations, gas
furnaces and electric furnaces, direct resistance heating is also used.
In Forge heat-treatment shop forgings undergo normalizing, thermal refinement and
isothermal annealing
Additional operations – shot-blasting, straightening and embossing
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Automatic line L-6417
Equipment characteristics: 2 lines for pressing of large parts up to 160 kg
Country of origin: Russia (Voronezh)
Forcing: 12 500 tons
Capacity: 40 – 70 pcs/hour
Products: Front axle beams, various crank-shafts
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Hot forming automatic machine “HATEBUR АМР-70”
Equipment characteristic:
Production of forgings:
-Projected diameter up to 147 mm,
-height from 15 to 80 mm,
-Inner diameter of rings at least 25 mm.
Country of origin: “Hatebur” (Switzerland).
Forcing: 1 500 tons
Capacity: 2 400 – 7 200 pcs/hour
Products: Gears, flanges, rings
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“EUMUCO” automatic line
Equipment characteristics:
2 lines consist of press КР 3150, forge-rolling machines and
induction installation for heating of blanks. Production of blanks
weighting from 1 to 3,5 kg and length up to 225 mm.
Country of origin: “Eumuco” (Germany).
Forcing: 3 150 tons
Capacity: 600 pcs/hour
Products: Connecting rods, cylinder and piston parts, levers, yokes, flanges,
cross-pieces
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Transverse v-shaped rolling automatic line
Equipment characteristic:
Production of rolled forgings by method of hot plastic deformation:
-diameter 53-100 mm;
-length 145-500 mm;
-Maximal weight of a blank - 11 kg.
Country of origin: JLLC “ATMengeering” (Belorussia-Minks)
Forcing: 40 tons
Capacity: Pair rolling – 180-400 pcs/hour, single rolling – 90-200 pcs/hour
Products: Shafts, axles
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Other equipment
Crank-type hot forging presses 630-6300 tf
(propeller-shaft yoke, gears, brackets, connecting rods,
flanges, shafts, levers, etc. from 0,3 to 20 kg. Heating of blanks
is done in induction-heating installations)
• Horizontal forging machine from 250 to 2000 tf (gears,
shafts, axle shafts, rear axles from 0,1 to 30 kg, heating of
blanks in gas furnaces)
• Pneumatic drop forging hammer 1 000 kg.
(levers, yokes, etc. from 0,035 to 3 kg. heating of blanks in gas
furnaces)
• Rolling-on machines for production of steering shaft
and steering linkage rod
• Electroforging machines for heading of blanks for
pressworks
• Bending machines for production of stabilizer rods
• Forge-rolling machines
• V-shaped rolling machines
• Trimming and embossing presses.
List of other equipment:
Extra:
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Auxiliary equipment
Control and measuring equipment
Hardness gages (HB) – measurement of products hardness when conducting heat treatment quality
control
Magnetic flow detector (made by CGM company – Italy) – is used for detection of defects in product
material
Laboratory and research equipment
Microscopes OLIMPUS GX51, Japan – are used for metallographic examinations
Tensile testing machines МЕТRОТЕSТ, pendulum testing machines – are used for measuring of ultimate
strength, yield point, impact strength and for testing other mechanical properties of products
X-ray fluorescence spectrometers ARL – are used for chemical examination of materials
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Support production
Production of dies for hot forming,
weight up to 2 tons
Production of various measuring
tools and devices
Die repair technology by weld-on
method
Development of management programs for CNC machines
(CAM System)
Power SHAPE (Delcam)
Power MILL (Delcam)
Work NC
TECHTRAN
Modeling and design (CAD System)
- CATIA V5
- AUTOCAD
- DEFORM
Products
Software
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Quality
Certification
Forgings (Forge)
ISO-9001
Compliance with international standards
Выполнение требований потребителей достигается за счет приведения процессов производства
Дивизиона Автокомпоненты в соответствие со стандартами ISO 9001 и ISO/TS 16949
Company success at the market
Product competitiveness
Rise of the company prestige and status
Build-up of the personnel motivation
Certification plan
Forgings (Forge) 2016
ISO/TS 16949
ISO 14001:2004
BS OHSAS 18001:2007
Certification
GAZ OJSC
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Thank you
for attention!
Lenina Avenue 88, Nizhny Novgorod,
Russia 603004, Tel. +7 (831) 299 09 90,
fax: +7 (831) 290 81 89
Epshteyn Kirill – Director of Autocomponents
Division
e-mail: [email protected]
Alexey Zaytsev– Director for Development
Autocomponents Division
e-mail:[email protected]
Nikolay Raytsyn - Director for Sales,
Autocomponents Division
e-mail:[email protected]
www.gaz.ru