SMX radial forging technology, designed and built by SMS group, is particularly suited for the aerospace industry, where high-quality forged components are essential. This technology ensures the reproducibility of products and achieves a high degree of automation, crucial for meeting the stringent demands of aerospace applications.

By integrating advanced automation and precise control systems, SMX radial forging technology enhances the consistency and quality of forged parts, for example those made from high-strength alloys and hard-to-form materials such as titanium.

The flexible control offered by hydraulic drive systems allows for precise manipulation of material deformation, ensuring optimal mechanical properties and homogeneous microstructures. These innovations not only reduce costs and improve energy efficiency but also guarantee the reliability and safety of aerospace components thanks to meticulous process control.

Compact drive concept: A new space optimization solution for hydraulic systems, enhancing both safety and process stability

Hydraulic presses, particularly radial forging machines, require a significant amount of space for extensive systems, often necessitating large, dedicated basements for installation. In the context of SMX lines, the choice between hydraulic and mechanical drive systems impacts the efficiency and quality of the forging process. Hydraulic drive systems offer a more adaptable approach to managing the resistance of the material during deformation, ensuring better deformation and enhancing workpiece quality. SMS’ new compact drive system builds on the advantages of hydraulic drive concepts with reduced spatial requirements.

Subject to ongoing development, the hydraulic concept has been optimized and now offers advantages in terms of spatial requirements and assembly times in the hydraulic room. The compact drive concept means significantly less space is required as essential hydraulic components are integrated into a compact, pre-assembled unit, thereby streamlining the installation process and reduces the time and effort needed for on-site assembly.

Energy-efficient innovation: Dual pump system with integrated flywheel and frequency inverter

Central to SMS group’s innovation is the dual pump configuration, where a single motor drives two main pumps. This design enhances efficiency by reducing the number of motors needed. A flywheel is integrated into the motor pump together with a frequency inverter. The flywheel acts as a mechanical energy buffer and eliminates electrical peak loads. The frequency inverter allows the pumps to operate at an ideal efficiency level, enabling the motor to be downsized. By that, peak load on the electric grid can be reduced significantly resulting in overall reduced OPEX costs.

The new compact drive design with flywheel offers several advantages:

• Space and cost efficiency: The hydraulic room space is reduced by 50 percent, and Piping weight is minimized by 65 percent.
• Operational efficiency: Energy consumption is approximately 30 percent lower, directly impacting operational expenses (OPEX).
• Maintenance accessibility: The layout ensures optimal accessibility for maintenance tasks, minimizing downtimes and enhancing system reliability.
• Dual pump configuration: A single motor drives two pumps, improving efficiency and reducing motor requirements.
• Smaller press cylinders: The number of pumps is reduced by up to 25 percent, meaning fewer hydraulic and electric components and reduced oil volume.

Advantages of hydraulic drive systems over mechanical drive systems

Mechanical drive systems typically operate with fixed penetration speeds, limiting their ability to adapt to varying material requirements. The stroke of a mechanical drive influences the penetration speed into the material, but this speed can only be adjusted in a very narrow range. Consequently, mechanical systems may struggle to accommodate the specific needs of different materials.

In contrast, hydraulic drive systems provide flexible control over the penetration speed. With the hydraulic system, the ram speedcan be adjusted to achieve the desired speed, allowing for precise manipulation of material deformation. This flexibility is important when working with materials such as titanium or Ni-base alloys, where controlled deformation is essential to achieve optimal mechanical properties. Rapid and slow penetration speeds can lead to varying strengths and microstructures. Hydraulic drive systems offer a more adaptable approach to managing the resistance of the material during deformation.

Why controlled material deformation is important for certain manufacturing processes

A flexible approach to managing material resistance during the deformation process is particularly crucial for aerospace-relevant materials such as titanium and Inconel, where the range of applicable forming conditions is very narrow. The hydraulic drive allows for precise control of the velocity, position, and force, unlike the stroke of a mechanical forging machine, which is always identical as it is determined by the eccentric drive. Further, the precise control capability offered by the hydraulic drive concept enables homogeneous temperature distribution and reduces the risk of material surface cracks. For instance, titanium can develop an undesirable grain structure, commonly referred to as a “spaghetti structure,” if the deformation speed is not appropriately selected. Only a hydraulic drive provides the necessary control.

By precisely managing the material deformation process, manufacturers can achieve the desired mechanical properties and microstructures, which are essential for the reliability and safety of high-performance materials such as titanium and Inconel. This control helps prevent defects and inconsistencies that could compromise the functionality and longevity of the final product.

Automated line control enhances precision and efficiency in aerospace forging processes

The production of aerospace components from nickel-based and titanium alloys requires precise process control. These materials demand meticulous forging processes to ensure optimal mechanical properties and microstructures.

Typically, this involves a forging line that includes an open-die forging press and a radial forging machine. The integration and precise coordination of these machines are crucial for achieving the desired product properties, ensuring components are forged to exact specifications for improved overall quality and performance.

SMS has implemented an automatic line control system, covering all long forging products requiring high automation and capacity, which automates machine operations and integrates material handling and tracking between furnaces, open-die presses, and radial forging machines. This system enhances process control and reduces human error, moving towards “operator-free forging” and maximizing efficiency and precision. This advancement marks a significant leap in forging technology, particularly in the aerospace sector.

SMS group supplies complete forging lines with tailored solutions and digital integration

SMS group is the only plant manufacturer capable of delivering a complete forging line from a single source. This includes high-speed open-die forging presses, SMX hydraulic radial forging machines, forging manipulators, and an integrated production control system. The ability to source a complete forging line offers customers advantages in terms of efficiency, customization, and digital integration.

Comprehensive service package: This ensures that all components of the forging line work harmoniously together.

Accelerated delivery: By sourcing all equipment from a single supplier, customers benefit from faster delivery times.

Simplified commissioning: Customers experience a smoother and quicker commissioning process, allowing for earlier production.

Tailor-made solutions: SMS’ broad portfolio of mechanical and service equipment allows for greater flexibility in designing custom solutions to meet specific customer needs.

Digital integration: The ability to integrate digital solutions throughout the forging line facilitates better monitoring, control, and optimization of the production process.

Uniformity of spare parts: Having uniform spare parts across the entire forging line simplifies maintenance and reduces inventory costs. This consistency ensures quicker repairs and replacements, minimizing downtimes.

Author

Dr. Martin Wolfgarten
Head of Product Management & Product Development
Forging Plants
SMS group