A. Benevenuta & C. S.p.a. ordered a 2,500-ton mechanical forging press from Farina, a Schuler affiliate. The company produces hot-forged steel components for the automotive industry near Turin, Italy. The parts are used in suspension systems, transmissions, engines and brakes in passenger cars, tractors, trucks and earth-moving machinery. The press force of the Benevenuta production lines ranges from 1,200 to 2,500 metric tons.

In the hot and warm forging of steel, there is a clear trend to replace graphite-based die lubricants with synthetic lubricants. This is driven by the need for cleaner work environments, easier handling and to avoid graphite-induced galvanic corrosion of equipment.

Schuler and its affiliate Farina demonstrated what the companies say is the world’s largest mechanical forging line to an international group of 60 forging experts. A live video stream transmitted from the production site in Suello, Italy, highlighted the features of the 16,000-ton press, which has a stroke of 600 mm, in action. The press will be delivered to Germany’s thyssenkrupp Gerlach. Due to its Scotch Yoke design, the press has a total height of 14 meters – making it much smaller than conventional presses. This enables high off-center loads and a high number of strokes. From the outside, the GLF-type machine looks like a conventional press, including the flywheel, clutch and crown gear. However, the Scotch Yoke directly works in the slide, which is the reason for the compact design.

U.S.-based suppliers can optimize processes, uptime and cost for the long haul with responsive expertise and readily available parts and service.

Schuler Service repaired two machines damaged in a fire at Mühlhoff Umformtechnik, an automotive supplier in Uedem, Germany. As a result, part production on a new 2,000-ton press from the TSD series can also start on time – all within just 12 months of the fire. Because drive components with long lead times were already accessible, Schuler was able to shorten the time to commissioning by three months. This happened even though the experts on site had to contend with challenges such as the foundation, which was designed for the previous and significantly smaller 800-ton line.

Schuler will deliver a 16,000-ton forging line, which includes a Farina forging press, to thyssenkrupp Gerlach. Internal assembly for the 16,000-ton line – one of the largest mechanical machines in the world, according to Schuler – has been completed at Farina’s facility in Suello, Italy. After the test run, the components (with a total weight of 1,700 tons) will make their way to thyssenkrupp Gerlach’s forging plant in Homburg, Germany. Production is expected to start in 2022.

When it comes to forging research, it turns out that size really does matter. The bigger the press, the lower the chance of using it for experimentation and the higher the costs associated with the research.

The COVID-19 pandemic has changed the forging landscape –seemingly overnight. With many in the industry initially expecting the impact to last a matter of weeks, most forgers are now preparing for a much longer recovery period that will likely last into early 2021.

In the manufacturing world, many people use technology readiness as a means of describing the journey within the valley of death, the gap between proof of concept and first use in the operational environment.

Germany’s Kaiser Aluminium-Umformtechnik GmbH, a manufacturer of forged-aluminum components for small- and medium-sized products, successfully started up its first Schuler servo screw press. The system will be primarily used to produce complex chassis components for the automotive industry. The investment further expands Kaiser Aluminium-Umformtechnik’s market position as a competent partner for forged parts and components in the aluminum sector.