FLANGES AND PANELS BUSINESS FIELD.
OUR FLANGES AND PANELS.
From a small flange for exhaust gas return systems to a single-component head flange for five-cylinder engines, our comprehensive product range covers all conceivable types of flanges and panels.
INSIGHTS INTO FLANGE PRODUCTION.
CASE STUDY / VOLKSWAGEN AG.
BUSINESS FIELD FORMING FLANGES
CASE STUDY.
Customer
Volkswagen AG
Product: Forming flanges
PROJECT OVERVIEW.
Project
Connection joint between turbocharger and exhaust gas system
To-dos
Develop manufacturing concept, prototypes, volume production, process monitoring
SOP
2010
Individual parts produced
> 16,000,000 pieces
PROJECT CHALLENGE.
- To substitute a forged part
- Material hardening by forming
- Zero-error target
SOLUTION CONCEPT.
- Appropriate material cross-sections, machining of just the sealing surface
- Machine concept precisely aligned to the forming flange
- Continual process monitoring by means of structure-borne sound, camera systems and eddy current
Know-how + digitalisation x 16 million parts = zero ppm.
Case Study / Mercedes-Benz Group AG.
BUSINESS FIELD FLANGES
CASE STUDY.
Customer
MERCEDES-BENZ GROUP AG
Product: Flanges
PROJECT OVERVIEW.
Project
Exhaust manifold flanges
To-dos
Component optimisation for non-cutting machining
SOP
2012
Individual parts produced
> 16,000,000 pieces
PROJECT CHALLENGE.
- Material 1.4301 in sheet-metal thickness of 10 mm
- Drill-hole diameter only 70% of the sheet-metal thickness
- > For cost reasons, no machining outside the sealing surface
SOLUTION CONCEPT.
- Multi-step fine blanking tool
- Daisy-chain grinding process with 100% inspection using camera systems