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Page 1: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,
Page 2: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,

WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com 3WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com2

HOW WE SPARK INNOVATIONWellman Products Group brings incredible energy and integrity to each and every application. We have the experience and capability, you have the product

and performance need. Together, we have a mutual goal—solve the problem! This focus on a common goal, and the enthusiasm we bring, createsan intensity, an Engineering Synergy, which sets us apart.

REACHING ACROSS THE WORLDOur products are sold to manufacturers in more than 50 countries. In turn, their products are used worldwide. We

support this effort with a commitment to excellence and unmatched product performance.

APPLICATION: MOTORSPORTSThe winning edge in racing often goes to the team with the best brakes ... and drivers who know

how to use them.

Our revolutionary racing brakes can operate safely at temperatures exceeding 1400º C whilemaintaining the highest coefficient of friction available. These materials are breaking track records

on nearly every circuit.FROM 1925 TO TOMORROWIn 1925, Henry Ford called on us to develop the transmission linings for his Model T.

Today, our products are called on to safely stop the world’s most advanced aircraft. Hundreds of thousands of pounds... Hundreds of people ... Braking at over a hundred-plus miles an hour ... Hundreds of times.

To ensure consistency, our worldwide facilities employ a Total Quality Management System that meets our demandingcustomers’ requirements.

INNOVATION

APPLICATION INNOVATION OPTIMIZES PERFORMANCE

• Critical Functions Worldwide• Global Resources, Specific Focus• Improving Motion Control System Performance

Our products are the friction components that go into the brakes, transmissions and clutches ofa world on the move ...

Planes ... Trucks ... Buses ... Cars ... Construction ... Mining ...Industry ... Racing ... Recreation ... Logging ... Lifting ... Farming ...Starting ... Stopping ... Changing Directions ... Shifting Gears.

Wherever there’s mechanical motion, there’s an application for one of our products.

We engineer and manufacture friction products for thousands of these applications,touching the lives of millions of people every day.

Innovation:Breakthrough Materials

Our Original Equipment brake, clutch and transmission frictioncomponents provide flawless performance in some of the mostcomplex, severe-duty applications in the world.

Page 3: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,

WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com 5WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com

ENGINEERING

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ENGINEERING SYNERGY CREATES RESULTS

• Your Application Requirements• Wellman Talent and Experience• Sparking Innovative Solutions

We know mining vehicles, construction equipment, aircraft, trucks, presses ... and the rules of engagement.

When a clutch engages ... when a brake engages ... performance characteristics must be specific,predictable and repeatable:

Coefficient of Friction • Heat • Friction Life • Matrix Strength • Fade • System Efficiency

Engineering these performance characteristics into a final product is a complex challenge.That’s where your Wellman team excels.

WE FOCUS ON YOUR APPLICATIONOur Product Managers are supported by dedicated R&D, Design and Application Engineers, as well asskilled prototype and model shop craftsmen ... and manufacturing associates on the plant floor. You havea ready-made team with the talent and desire to meet your toughest requirements.

We are organized into Product Management Groups:• Aircraft–Commercial, Passenger, Military, Cargo, General Aviation• Heavy Equipment–Graders, Bulldozers, Loaders, Trucks, Cranes, Mining Machines• Racing–Stock Cars, Sports Cars, Indy Cars, Sprint Cars• Specialty Vehicles–Motorcycles, Snowmobiles, ATVs, Mountain Bikes• Trucks–On- and Off-Highway• Industrial Machinery–Printing Presses, Stamping Presses, Press Brakes, Shears• Agricultural Equipment– Tractors, Combines, Harvesters

ENGINEERING YOUR SOLUTIONWe start with your application and draw from our experience—tens of thousands of engineered materials developed and tested. Yet “off the shelf” solutions are

often not good enough. You’ll find that with the Wellman product team concept and intense effort, your new material formulations are developed efficiently... and proven thoroughly.

We apply materials ... to process ... to prototype ... to part ... to end use:

• Ceramic • Sintered Metallic • Carbon Semi-Metallic • Graphitic • Paper • Exotics

We constantly develop proprietary materials, many of which do not fit neatly into any classification, but do provideunmatched performance.

APPLICATION: TRUCK CLUTCHESIncreased power levels at clutch engagement created a costly repair problem. Our

challenge: Develop a new material, test it and get it into production—fast!

Using advanced optimization techniques, we perfected an innovative product combiningmaterials and process breakthroughs. Results:

• Flywheel wear reduced by 75% • Friction life extended by 30%• Superior coefficient of friction • Driver fatigue reduced

And we did it ahead of schedule, within targeted costs.

Our management team and application engineers work with you todeliver the performance characteristics you need.

Innovation: Rapid Response,New Material!

Page 4: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,

WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com 7WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com

MATERIALS

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PROVING MATERIALS PERFORMANCE

• Beyond Real World Requirements• Combining Physics and Chemistry• Testing with the Industry’s Most Extensive Facilities

How far should your material be pushed? The answer lies in creating the forces that duplicate, then exceedsthe operating environments.

BUILDING COMPOSITE PROPERTIESThe science of friction materials begins at the sub-atomic level. Each material is a scientificformula, and a precise process, subject to the dynamics of physics and chemistry.

For example, one material may have the exact chemistry of another. While one performsflawlessly; the other tears apart the opposing surface. The difference: the particle shapeof one ingredient.

CREATING TOMORROW’S MATERIALSWe are at work today perfecting the higher energy, lighter weight, and recyclable materials for tomorrow.

Our prototyping facilities can duplicate our manufacturing lines, so when your new material is ready,we can quickly scale up from development to full production.

APPLICATION: “HOT ROD”MINING TRUCK BRAKES

A mine owner complained of failing wet brake components on his giant ore hauling trucks.

Operators ran fully loaded trucks at 18 mph downhill, while the operating specificationcalled for a maximum of 8 mph. Merely telling the drivers to “slow down” would be impractical

and ineffective.

Re-engineering brake design was not an option, so we developed a new paper formulation that withstandsmuch higher operating temperatures and shear forces, and does not fade.

The result: Reduced downtime, higher productivity,motivated drivers

and improved safety and profitability for the mine owner.

THE PROOF YOU NEEDWe prove beyond a doubt that our products will perform in your application. With the most extensive frictiontesting capabilities in the industry, we are able to bring your application to life.

Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature, and engagement cycleof your application—wet or dry.

Temperatures at engagement can reach several thousand degrees. Failures can be dramatic. But with constant testing and development,failures can be confined to the lab.

Because proving applications involves so many long-term repetitive tests, we created computer-aided testing cells to test around the clock.

Our dynamometers duplicate the most severe operating conditions toconfirm product performance.

Innovation: Cool Runners

Page 5: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,

WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com 9WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com

MANUFACTURING

8

MANUFACTURING WORLD-CLASS FRICTION

• Industry-Leading Capabilities• Building More Advanced Technologies• Promoting Can-Do Spirit

Quality and delivery are two of the reasons Wellman is the leader in friction—for example, we supply the vast majority ofclutch buttons worldwide.

MAKING ANSWERS WORKMany friction components begin as a variety of powder materials which are combined in properproportion, bonded in a matrix, and affixed to a metal substrate.

Our manufacturing processes include:

• SPC • Mixing and Blending • Molding• Die Cutting Impregnated Paper • Sintering • Curing• Metal Stamping • Laser Cutting • Powder Metallurgy• Bonding • Coining • Grinding• Grooving • Machining • Gear Shaping• Testing

These processes produce millions upon millionsof parts for some of the toughest

applications and mostdemanding customerson earth.

CONTINUING INVESTMENTSWhen you visit our plants, you’ll see bank after bank of machinery, from molding presses to stamping presses, gear shapers to surface grinders, bell furnaces

to curing ovens, laser cutters to coordinate measuring machines ... You may even see foundations being set for new equipment at an impressive pace.Capital investment, incorporating the latest in automation, is an exciting fact of Wellman today.

We continually invest millions of dollars in state-of-the-art manufacturing equipment, including computer controlled processes withSPC monitoring to ensure product precision and quality.

Growth requires a substantial investment in people. Continuous improvement is our goal, one that returnsquality dividends.

APPLICATION: MILITARY VEHICLE BRAKESThe manufacturer of a four wheel drive military vehicle wanted to broaden the vehicle’s

military applications by adding communications equipment and more armor.

These modifications doubled vehicle weight causing the brakes to virtually self destruct. ThoughWellman was not the original brake supplier, the manufacturer asked us to solve the problem.

We developed a heavy duty material similar to an aircraft brake product, adding pad surface area todissipate heat more efficiently. Mission accomplished!CREATING A WINNING SPIRIT

We do what it takes to get the job done ... design production machinery ... create technology ... refineprocesses. Innovation is an every day event on our factory floors.

Each factory’s innovative ideas and processes are enthusiastically shared ... across continents ... across oceans. So themanufacturing environments in all of our plants are charged with the positive energy of continuous improvement. Our peoplemake it work.

Innovation:Aircraft-Like Performance

Our investment in automation provides the capacity andflexibility to economically produce even short runs.

Page 6: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,

WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com 11WELLMAN PRODUCTS GROUP PHONE: 440-528-4000 www.wellmanproducts.com

TRADITION OF SUCCESS

10

UNSURPASSED QUALITY EARNS REPEAT BUSINESS

• Certified and Preferred Supplier• World’s Leading Equipment Makers• Delivering Consistent Performance

We work hard to earn our customers’ business ... and their respect. We work even harder to keep it.

That’s why we’ve been aggressive in pioneering and implementing formal Total Quality Management(TQM) and Statistical Process Control (SPC) programs that mesh exactly with our customers’quality requirements.

As Certified and Preferred Suppliers to the world’s leading equipment manufacturers, weconsistently meet or surpass the toughest standards for precision, quality, delivery and value.

WE DELIVERQuality doesn’t end with materials and processes. We also work hard to deliver the product.

Customers operating in Just-In-Time environments and requiring millions of parts per year rely on our promptdeliveries to keep their lines running smoothly.

PUT US TO WORK FOR YOUWe are your world-class source for severe duty, high performance and extreme durability friction materials. Contact us today and find out how

Wellman’s advanced friction solutions can work for you.

THE WELLMAN ADVANTAGELOGISTICS• Manufacturing plants on 3 continents• Worldwide Distribution

BEST IN BUSINESS PRACTICES• Six Sigma Culture• B to B Commerce• World Class Engineering• Global Customer Care• MFG Pro–QAD

ECONOMIC ADVANTAGE• Global Pricing• Global Sourcing• Full Service Supplier

QUALITY ASSURANCE• TS 16949 Certified• ISO 9001 Certified• QS 9000 Certified

We provide superior engineered friction solutions for virtually anysevere-duty or high performance application

Page 7: REACHINGACROSSTHEWORLD - Cairo Hydrauliccairohydraulic.com/products/Wellman/2008 Wellman... · Using dynamometer simulation, we can duplicate the precise energy, the torque, temperature,

www.wellmanproducts.com

WELLMAN PRODUCTS GROUP6180 COCHRAN ROAD SOLON, OH 44139 USA • PHONE: 440-498-4000 FAX: 440-528-4099 • [email protected]