Bulletin 2/2010 - Siempelkamp NIS

Ultrasonic inspection
optimized the construction according
to the latest technology and a given
maximum component part weight.
The Siempelkamp engineers modeled
statics and dynamics according to the
Finite Element Method. During this
process multi-body contact systems were
used to determine the interdependencies
of the different components. Afterwards,
the engineers determined the stress levels
of each part in order to meet the high
quality requirements of the customer with
an optimally calculated part.
In the next step, a prototype was
developed on the computer at the
foundry. The entire manufacturing process
of the castings for Alcoa was simulated
from the pouring to the solidifi cation to
the calculation of the internal stresses in
the fi nished casting. The process resulted
in parts with an optimal design in regard
to quality. Due to modern construction
and material properties, the cast parts are
fatigue resistant. The challenge for the
designing engineers was that the new
parts, which incorporate 50 years of technological
development, had to be exactly
in accordance with the old parts.
Since Alcoa Forging & Extrusions was
going to perform the installation of the
cast parts on site, it was important that all
parts fi t into the existing press upon
arrival. For parts with a length of 10 m,
accuracy to within 0.1 mm had to be
assured!
August 2010: the hot phase – a record
casting
After all calculations and simulations
were completed, the Alcoa parts literally
entered the hot phase: On August 20,
2009 the Krefeld team cast the fi rst
SIEMPELKAMP | FOUNDRY/MACHINERY AND PLANTS
foundation beams. After all foundation
and press beams were cast, the parts
were machined on large-scale machines,
capable of processing components with a
clamping length of 22 m (72 ft) at the
Krefeld factory.
Finally, on July 8, 2010 the top act was on
the agenda: Since May 2009 Siempelkamp
Foundry had been holding the record for
the world‘s heaviest ductile iron casting
with a raw casting weight of 255 t. Now
this record was to be surpassed with 283 t
of molten iron for the Alcoa closed-die
forging press. With rapt attention the
Siempelkamp Foundry employees had
made all the necessary preparations for
the casting of the upper beam with a raw
casting weight of 260,000 kg.
283 t of molten iron with a temperature of
1,350°C (2,462°F) distributed over fi ve
pouring ladles was waiting to be poured.