Together with an integrated process and production control system, these machines form an integrated and automated forging line, enhancing production capabilities and meeting growing demand from the aerospace and medical sectors. They also widen the product portfolio from thin titanium bars to include thick bars and plates, which were previously sourced externally, not produced in-house.
The forging machines supplied by SMS to Perryman include a 40/45 MN high-speed open-die forging press in the pull-down design and an SMX 500/15 MN hydraulic radial forging machine with two forging manipulators. The open-die forging press is utilized to forge cast titanium ingots initially to the required size, allowing them to be finish-forged in the radial forging machine. These machines are specifically designed for processing titanium ingots and producing bars of various shapes and in lengths of up to 14 meters.
The two forging machines are complemented by a fully integrated process and production control system that encompasses the entire forging line, enabling a fully automated and integrated forging process. The SMS’s MIDIS system manages and coordinates all production sequences, ensuring smooth operations and smart production planning. ForgeBase® and Comforge® technology packages allow for precise configuration of forging strategies by considering material properties and process parameters, with real-time data evaluation and visualization allowing for continuous optimization during forging. SMS-Metrics and Smart Alarm systems monitor machine performance to detect anomalies early, thus minimizing any downtime. The Maintenance Advisor ensures preventive maintenance, improving machine availability and production reliability.
Unique capability
“This project demonstrates SMS’s unique capability to implement such complex, integrated systems,” emphasizes Klaus Opgen-Rhein, Project Manager at SMS. “From concept to commissioning, our expertise in mechanical engineering and automation enables solutions few can deliver.”
This comprehensive package is designed to enhance Perryman’s production capabilities, enabling the company to manufacture products that were previously sourced externally. It allows Perryman to transition seamlessly from outsourcing to in-house manufacturing with a small core of trained personnel. The automation solutions ensure precise process control, which is essential for meeting the stringent requirements of safety-critical applications demanded by the aerospace and medical sectors.
Dr. Thomas Winterfeldt, Head of Forging Plants at SMS, emphasized the collaborative success: “This installation demonstrates how our digital solutions are transforming forging technology. It shows how true partnership customer and equipment supplier can push technological boundaries. The good cooperation between the two teams has led to this success and strengthened the partnership.”
