Hirschvogel自动变速器最新锻压技术介绍2013

• Cost efficient steel for transmission • 高性价比的变速箱零部件用钢 components • Forged Splines and Gears • Conclusion • 锻造花键与齿轮 • 总结
2 © Hirschvogel Holding GmbH
Hirschvogel Worldwide
Outline
• Introduction • Advantages of Forging Technology • Cold forged transmission shafts • Lightweight Design: Hollow Shafts • 简介 • 锻造技术的优势 • 变速箱冷锻轴 • 轻量化设计：空心轴 轻量化设计：
413 Mio. € 194,000 t 1,819
Process Spectrum:
Hot forged Warm forged Cold forged Rotary swaging Aluminum (hot) forming Mechanical processing
Weights
4
Stand: 2013 - I
4,2
20,8
2,6
3,8
19,2
2,4
Energy Balance in %
Summary: Forging and Steelwork 总结：锻造与钢厂
Additional Energy Use/ 额外能耗: • Transport of Scrap / 废料运输 • Tool wear/ 刀具磨损 • Energy and tools for turning / 机加工能耗与工具损耗
Source: Hirschvogel 10 © Hirschvogel Holding GmbH
Output Shaft 输出轴
Machining Allowance
Machining Allowance
0,7
Outputshaft 1
215 HB Spline Rolling Area
Source: Hirschvogel 11 © Hirschvogel Holding GmbH
Properties of Forgings
• Mechanical properties depend on orientation of fiber flow • Increased impact energy in parallel direction • 机械性能取决于取样方向与流线方向的 相互位置 • 相同的取样方向与流线方向提高试样强 度
0.6 bis ~ 6 kg
0.1 bis ~ 11 kg
0.1 bis ~ 11 kg
© Hirschvogel Holding GmbH
Distribution Product Groups 2012
Gas and Diesel Injection Others Chassis
1% 21 % 5百度文库 32 %
17 % 23 %
Engine
Transmission
Powertrain
6
Stand: 2013 - I
© Hirschvogel Holding GmbH
Forging Processes
20° C Cold Forging 冷锻
720° - 950° C C Warm Forging 温锻
1200° C Hot Forging 热锻
Cold forged shafts
• Output shaft • Forging in several stages • Combination of processes: • Forward extrusion • Reducing • Upsetting • Backward can extrusion • Ironing • 输出轴 • 多工位锻造 • 组合工艺： • 正向挤压 • 缩径 • 墩粗 • 反向挤压 • 拉伸
1952 Foundation 2008 Joint Venture 55 Mio. € (150 Mio. BRL) 24,600 t
778 Mio. € 268.000 t 3,894
(inclusive Holding)
77 Mio. € (100 Mio. USD) 32,700 t
291
122
3
Stand: 2013 - I
© Hirschvogel Holding GmbH
Company Data
Data
Total Group
(consolidated)
Germany
Germany
Germany
Germany
Poland
Year of Foundation Total Sales 2012 Production 2012 Employees 2012
Advantage of cold forging
• Hollow shaft • Red: Raw part hot (13.437 kg) • Blue: Raw part cold (8.012 kg) • Yellow: finished part (4.495 kg) • 空心轴 • 红色：热锻毛坯（13.437kg） • 蓝色：冷锻毛坯（8.012kg） • 黄色：成品（4.495kg）
USA
India
China
Brazil
Year of Foundation Total Sales 2012 Production 2012 Employees 2012
(annual average)
1988
2010 5 Mio. € (315 Mio. INR) 1,800 t
2005 40 Mio. € (324 Mio. CNY) 14,600 t
137
139
161
▄▄▄▄ ▄▄ ▄
111
109
112
100
100
100
Hollow Shafts: Process Comparison
• Conventional manufacturing (A): Massive forging → drilling Disadvantage: high material input • Alternative manufacturing (B): Hollow forging without drilling Advantage: low material input • 传统工艺（A）： 实心锻造→钻孔 劣势：原材料消耗大
specimen 2 normal to fibre specimen parallel to fibre
10 9 8 7 Impact energy / J 6 5 4 3 2 1 0 16MnCrS5 Cf53 normal 1 normal 2 parallel
MnS-fibre
9 © Hirschvogel Holding GmbH
A
B
• 非传统工艺（B）：
中空锻压无需钻孔 优势：原材料消耗小
Drilling vs. hollow forging 钻孔 VS. 中空锻压
Source: Hirschvogel 17 © Hirschvogel Holding GmbH
Output Shaft
• • • • • Minimum diameter: 37mm (1.46 in) Maximum diameter: 108 mm (4.25 in) Weight: 6.4 kg (14.11 lbs) Material: 20MnCr5 Manufacturing: multi-stage cold forging process in combination with machining • Weight saving by machining not feasible • • • • • • 最小直径：37mm（1.46in） 最大直径：108mm（4.25in） 重量：6.4kg（14.11lbs） 原材料：20MnCr5 生产：多工位冷锻结合机加工 通过机加工进行减重不可行
Forged Transmission Components for Lightweight Design and Ressource Efficiency
Dr.-Ing. Stephan Weidel Dr.-Ing. Hans-Willi Raedt
1 © Hirschvogel Holding GmbH
Driving shaft 主动轴
Source: Hirschvogel 13 © Hirschvogel Holding GmbH
Cold forged shafts
• Extrude / cross rolling Conclusion: Different fibre flow • 挤压 / 横轧 总结: 材料流向不同
Cross Wedged 横轧
14 © Hirschvogel Holding GmbH
Extrusion 挤压
Comparison of Forging Processes
Process Chain 工艺流程 Forging from a Transmission Shaft 变速箱轴的锻造 Steel Bars from Steelsupplier 钢材供应商提供钢棒 LD-Steel LD-钢材 Charge Weight 使用材料重量 kg Hot Forging 热锻 Warm Forging 温锻 Cold Forging 冷锻
Hollow shaft 空心轴
Source: Hirschvogel 12 © Hirschvogel Holding GmbH
Advantage of cold forging
• Driving shaft • Red: Raw part hot (4.021 kg) • Blue: Raw part cold (3.318 kg) • Yellow: finished part (2.281 kg) • 主动轴 • 红色：热锻毛坯（4.021kg） • 蓝色：冷锻毛坯（3.318kg） • 黄色：成品（2.281kg）
Source: Hirschvogel 7 © Hirschvogel Holding GmbH
Potential for Lightweight Design
weight reduction
cost efficiency
forging technology
high strength
8 © Hirschvogel Holding GmbH
240
615
Process Spectrum:
Hot forged Warm forged Cold forged Rotary swaging Aluminum (hot) forming Mechanical processing
Weights
5
Stand: 2013 - I
0.5 bis ~ 20 kg
Source: Hirschvogel 15 © Hirschvogel Holding GmbH
Energy Value 能耗 kWh
CO2 – Value CO2排放 kg
Horizontal with Burr 横锻有飞边
5,2
25,9
3,2
Vertical without Burr 垂直锻无飞边 Vertical without Burr 垂直锻无飞边
Charge Weight Energy Value CO2 – Value 使用材料重量 能耗 CO2排放 % % % Hot Forging 热锻 Warm Forging 温锻 Cold Forging 冷锻
Source: Hirschvogel 16 © Hirschvogel Holding GmbH
0.1 bis ~ 30 kg
0.1 bis ~ 11 kg
0.1 bis ~ 11 kg
0.1 bis ~ 8 kg
0.1 bis ~ 4.5 kg
© Hirschvogel Holding GmbH
Company Data
not consolidated
Data Total Group
(consolidated)
(annual average)
1938
1991 85 Mio. € 33,200 t 409
1999 236 Mio. € ----685
1999 51 Mio. € 9,800 t 156
2009 21 Mio. € 10,400 t 74
778 Mio. € 268.000 t 3,894
(inclusive Holding)