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ULUS METAL
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• 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
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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
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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
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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
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•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
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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