Bulletin 2/2010 - Siempelkamp NIS

SIEMPELKAMP | FOUNDRY/MACHINERY AND PLANTS 64 65
For Alcoa, Siempelkamp is a well-known
and trusted partner. Siempelkamp has
developed and built several forging presses
for Alcoa in the past. Both companies
can look back on a relationship of mutual
trust.
Among other parts, the scope of supply
for Alcoa consisted of 14 large cast parts
for the upper, cross and lower beams as
well as the foundation beams. For the
manufacturing of these replacement
parts, Alcoa had given three requirements:
Machining with two portals
Each new part had to fi t exactly into the
available space of the part to be replaced
and the connecting dimensions had to be
the same, it could not weigh more than
247.5 US tons (224.5 t), and had to be
fatigue endurable. Furthermore, the
scope of supply included custom parts
such as a 105 t die change plate, a 45 t
protection plate, miscellaneous centering
rings and stroke-limiting collars as well as
a guiding system for the cross beam. The
die change plate consisted of three metal
slabs (3,000 mm x 3,750 mm x 550 mm)
Machining on the large portal milling machine at Siempelkamp
that were welded together by electroslag
remelting.
From blue prints to simulation:
50 years of engineering innovation
The starting point for the production of
the new cast parts were blue prints from
the 1950s. Within the framework of the
order, Siempelkamp used these blue prints
to analyze the original design from the
1950s, carried out calculations according
to the Finite Element Method and