achievements and potentials in lightweight … · in lightweight and non-automotive applications ....

Dr. Martin Habert

CAPITAL MARKET DAY, OCTOBER 6TH, 2015

ACHIEVEMENTS AND POTENTIALS IN LIGHTWEIGHT AND NON-AUTOMOTIVE APPLICATIONS

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ACHIEVEMENTS AND POTENTIALS IN LIGHTWEIGHT AND NON-AUTOMOTIVE APPLICATIONS

SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 2

• Division Hydraulic

• Non-automotive applications

• Lightweight automotive solutions

SCHULER GROUP STRUCTURE

SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 3

6 DIVISIONS WITH GLOBAL RESPONSIBILITIES

SYSTEMS AUTOMATION SERVICE

AUTOMOTIVE INDUSTRY HYDRAULIC

Facts and figures

HYDRAULIC DIVISION

12.10.2015 SCHULER CORPORATE PRESENTATION 4

Technological and global market leader in hydraulic presses and forming systems

History: Schuler, Müller-Weingarten, Hydrap Products: Hydraulic presses and complete systems for cold

or hot metal forming, forging and composites production Applications:

Automotive (ca. 55 %), Railway (ca. 25 %), Aerospace, Heat Exchangers, General industry

Key Technologies: Hot Stamping Railway wheels Hydroforming Titanium Forming Fineblanking

1by 30.09.2013

Hydraulic division 2015 Sales ca. 150 Mio. €

Order Entry ca. 160 Mio. €

Order Backlog ca. 170 Mio. €

Employees 165

Markets

Europe ca. 30% Asia ca. 30%

Americas ca. 30% Russia ca. 10%

TRADITIONAL APPLICATIONS

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HYDRAULIC PRESS LINE @ JAGUAR, 2001

WHAT REALLY COUNTS

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HYDRAULIC PRESS LINE @ TODAY

Hydraulic presses: ….very high press forces ….at any position ….as long as necessary

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NON-AUTOMOTIVE APPLICATIONS

GROWTH MARKET RAILWAY

8

80

100

120

140

160

2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023

Freight rail Passenger rail Urban rail

Source: SCI Verkehr 2014, „Rail Transport Markets – Global Market Trends 2014-2023

Worldwide rail transport performance 2013-2023 [Index 100=2013]

100 = 10,711 billion tkm 100 = 3,536 billion pkm 100 = 448 billion pkm

12.10.2015

NON-AUTOMOTIVE APPLICATIONS

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SYSTEMS FOR RAILS SYSTEMS FOR AXLES SYSTEMS FOR WHEELS

RAILWAY

Upsetting Preforming Dishing Rolling

SYSTEMS FOR WHEELS FORMING SEQUENCE

SYSTEMS FOR WHEELS CLOSING THE GAP – NEW SCHULER WHEEL ROLLING MACHINE

Customer Shandong Heli / China • MH 10000 and 2x MH 5000 • Wheel Rolling Machine MHRV 180/80 • Tools • Automation and Line Control

2012

SYSTEMS FOR WHEELS COMPLETE FORGING LINE

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2007 2009 2011 2013 2015 20xx

NEW PRODUCTS CREATE NEW BUSINESS

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Order Intake Mio. € 1 I € 9.200.000.-

CUSTOMER CAF, SPAIN 2007

Hydraulic forging presses MH 10000 & MH 5000

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2 I € 3.200.000.-

CUSTOMER MWL, BRAZIL 2009

• Hydraulic forging press MH 3000

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3 I € 32.600.000.-

CUSTOMER SHANDONG HELI , CHINA 2011 Hydraulic forging presses

MH 10000 & 2 x MH 5000 Wheel roller MHRV 180/80 Dies & automation & auxiliary equipment

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4 I € 92.000.000.-

CUSTOMER KARDEMIR , TURKEY 2013 Sawing lines for billets Furnaces (Andritz Metals) Hydraulic forging presses MH 10000 & MH 5000 Wheel roller MHRV 180/80 Dies Machining equipment (FFG) Automation, line control, auxiliary equipment

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5 I € 52.500.000.-

NEW ORDER 2015 SCHULER & ANDRITZ METALS Hydraulic presses Wheel roller Dies, autom., aux. equipm

Schuler: € 36.500.000-

Rotary furnace and heat treatment (Andritz Metals) Andritz: € 16.000.000.-

SCHULER AEROSPACE TITANIUM AND SPECIAL METALS HOT FORMING

HOT DEEP DRAWING

12.10.2015 15 SCHULER IN-HOUSE SHOW "AEROSPACE" JULY 1-2 2015

SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 16

LIGHTWEIGHT AUTOMOTIVE SOLUTIONS

0

20

40

60

80

100

120

140

160

180

200

220

2000 2005 2010 2015 2020 2025

AUTOMOTIVE LIGHTWEIGHT DESIGN MOTIVATION

17 Source: ICCT 2014, Historical fleet CO2 emissions performance and current or proposed light commercial vehicle/light truck standard:s

LIGHT-DUTY VEHICLE STANDARDS ON CO2 EMISSIONS

Grams CO2 per km, normalized to NEDC

12.10.2015

Liters per 100 km (gasoline equivalent)

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8

7

6

5

4

3

2

1

Historical performance Enacted targets Proposed targets or targets under study

US 2025:

China 2020:

KSA 2020:

Canada 2025:

India 2021:

Japan 2020:

S. Korea 2020:

Mexico 2016:

EU 2021:

Brazil 2017:

97

117

142

97

113

122

97

145

95

138

AUTOMOTIVE LIGHT WEIGHT DESIGN MOTIVATION

12.10.2015 18

INFLUENCE OF THE WEIGHT TO FUEL CONSUMPTION AND PERFORMANCE

Rolling resistance

Acceleration resistance

Gradient resistance:

R

G

A

AUTOMOTIVE LIGHT WEIGHT DESIGN - MOTIVATION

12.10.2015 19 Source: Volkswagen

NETWEIGHT OF THE GOLF (1974-2013)

600

800

1000

1200

1400

1600

1 2 3 4 5 6 7

Netweight in kgDepending on model type and configuration

AUTOMOTIVE LIGHT WEIGHT DESIGN

12.10.2015 20

The multi-material body in white combines different components of light weight metals:

High-strenght steels

Cold and hotformed steels

Aluminium

Magnesium

Carbon fiber reinforces plastics

Less use of soft deep drawing steels

Material mix increases the complexity in the joining technology

CLEVER LIGHT WEIGHT DESIGN

THE DESIGN CONCEPT OF THE HYBRID CONSTRUCTION:

The right material – (depending on the function) at the right place – in the smallest amount possible!

AUTOMOTIVE LIGHT WEIGHT DESIGN

12.10.2015 21

SCHULER FORMING TECHNOLOGY FOR LIGHT WEIGHT MATERIALS

PRESSHARDENING HYDROFORMING COMPOSITES

Hardening

HIGH-STRENGTH STEELS FOR AUTOMOTIVE

SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 22

Steel qualities

HARDENING PROCESS IMPROVES TENSILE STRENGHT

Elon

gatio

n

Tensile strenght

PRESS HARDENING

12.10.2015 23

WHAT HAPPENS WITH THE MATERIAL? USIBOR, 1500 MPA, ELONGATION<10%, STRUCTURAL PARTS

Blanks are heated to 950 °C in a furnace. The heating time of 5 minutes is important to

achieve the proper material structure (austenite)

The heated blank has to be fed into the press as fast as possible to avoid cooling of the material by air.

The press has to close fast, form the part and keep it closed for several seconds.

During this time the cooling circuits in the upper and lower dies are cooling the part down to approximately 200 °C.

Forming and cooling down

Heating

Parts or Blanks

Martensite

Perlite

Austenite

Competence center press hardening

14/05/2014 FORD VISIT

PRESS HARDENING TURN-KEY SOLUTIONS FROM SCHULER

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Schuler Hot Forming - dies, prototypes & process - hydraulic presses & entire process - automation for press hardening line - Line control & integration of furnace

CURRENT SITUATION AND FUTURE NEEDS

12.10.2015 25

SIGNIFICANT INVESTMENTS FOR NEW LINES

Trend upwards

Number of hot forming parts per vehicle will increase from an average of 10 today to more than 30 in 2018

OEM experts say that by 2018 up to 600 Mio parts/year are needed

End of 2014: ca. 240 lines in operation

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50

100

150

200

250

300

350

1984 1988 1992 1996 2000 2004 2008 2012 2016

Today approx. 250 Mill.

Million parts/Year

3 Mill. 8 Mill.

Forecast 2018: 500 - 600 Mill

Hot Stamping Part Production

1/3 OF INSTALLED BASE BY SCHULER

25-30 NEW LINES PER YEAR

FOR THE NEXT 5-6 YEARS

NEW PRODUCT: HIGHEST PRODUCTIVITY AND ENERGY EFFICIENCY

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Production time = 20 shifts/ week x 8h / shift x 50 weeks/ year = 8000 h/year

Conventional others

PCH flex with EHF 1-4

Stroke Rate

OEE

Strokes / year

Energy per 1 Mio. Stroke

3.6 SPM

60 %

1,000,000

1,500 MWh Press only!

5.2 SPM

70 %

1,750,000

900 MWh Press only!

Demonstration & Training Technology development Prototype production Back-up line for customers

Servo TechCenter

SCHULER TECHCENTER 2015

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Göppingen, D I MSD 250

Erfurt, D I TST 1.600, TSD 1.100

Tianjin, China I TST 1.600

Automation TechCenter

Gemmingen, D I Crossbar Roboter 4.0

Canton, Mi USA I Crossbar Roboter 4.0

Hessdorf, D I Intratrans

Scope of Services

Hot Stamping TechCenter

Göppingen, D I PCH-Linie

Hydroforming TechCenter

Canton, Mi USA I Hydroforming-Presse

LOCATIONS

• Processing from the coil

• 3 cutting heads

• Flexible stacking

• Continous feeding

• Cleaning (class A)

• No tools

LASER BLANKING LINE SCHULER AUTOMATION

SOUTRAC WELDING LINE FOR HOT STAMPED DOOR RINGS

SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 29

ANDRITZ SOUTEC

SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 30

THANK YOU!