TPT November 2015

Technology News

Test run proves decisive PRECISION stampings require not only cutting-edge press and die technology, but also high-performance levellers: several rollers straighten the sheet metal as it leaves the coil and eliminate any defects – such as cross bows which cannot be completely avoided in production – with the aid of an alternate bending process.

The specific requirements for an optimum straightening process are defined by the material and finished component. In order to find the right machine, SKA and Schuler precisely defined which materials would be used in production for which end products. “Until the end of the 1990s we used levellers with nine rollers, as we used to produce guide rails from relatively soft materials,” recalled Guido Schneider, SKA’s chief technology officer. However, the requirements regarding materials and tolerances for part quality have grown steadily over the years, and this necessitated the use of classic multi-

SKA’s fine levelling machine is positioned upstream of a 400t press, also supplied by Schuler

given us any problems,” said Mr Schneider. “Looking back, I have to say that the test day was the decisive factor for us. Schuler proved that the fine leveller could straighten cross bows in exactly the quality we need. In the past, we often had to readjust the die on a press because the material properties changed within a few metres. Obviously, this also depends on the quality of the coil, but the Schuler device can generally balance out fluctuations so well that nothing is noticed in the die or product. I would definitely work together with Schuler again.”

roller levellers. However, even these machines were not completely suitable for the targeted production portfolio. Schuler then offered to run tests with different strips of material on a leveller for one day, in addition to providing on- site expertise. “It turned out that the number of rollers was not the decisive factor,” reported Mr Schneider. “In fact, a 17-roller machine with significantly higher rigidity was the better choice for us.” One year later, in June 2014, the fine levelling machine was finally put into operation upstream of a 400-metric-ton press supplied by Schuler – one of seven at SKA. The overall system not only increased output and part quality, but even decreased energy consumption. “The line has since been running without any downtime and has not

Schuler AG – Germany Fax: +49 7161 66 907 Website: www.schulergroup.com

With just 17 rollers, the rigid machine balances out fluctuations in the coil stock Photo credit: Schuler

Long life in aggressive solutions E BRAUDE is based in the UK and has been serving industry for more than 58 years. Traditionally it has been focused on the liquids and conditions other suppliers avoid, and its expertise is in aggressive and corrosive solutions that conventional equipment cannot withstand. which required an offline heating system in a new pickling facility. The heat exchanger had a high output of 400,000kcal/hr on a saturated steam system. Braude designed and built steam heat exchangers specifically to suit the tanks, while meeting the challenges of the cost profile.

Teflon™), and are designed to ensure long life in aggressive solutions. The product range includes tank and vessel heaters/coolers for use with steam, hot water or thermal fluids; chemical service pumps; external heating systems that are mounted outside the process tank to avoid clutter and to prevent damage by heavy workloads; and electric heaters and controllers.

Braude also recently undertook another contract in Asia to supply heat exchangers for the pre-treatment line for one of the largest galvanising plants in the world. All of Braude’s products are manufactured from high integrity chemically inert fluoropolymers (eg

Braude has been exporting for many years, and has recently increased its efforts in the Asian markets. One of the company’s strengths is the ability to tailor products to suit customers’ specific needs. Braude was recently approached by a company in India building a plant for a stainless steel tube manufacturer,

E Braude (London) Ltd – UK Fax: +44 1252 875281 Email: sales@braude.co.uk Website: www.braude.co.uk

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N ovember 2015