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EXTRUSION Heavy duty extrusion presses for large pr<strong>of</strong>ile applications Axel Bauer, SMS Meer GmbH SMS Meer, a member <strong>of</strong> <strong>the</strong> SMS group, is currently building several heavy extrusion presses for large pr<strong>of</strong>ile applications. Two <strong>of</strong> <strong>the</strong>se presses have a nominal pressing force <strong>of</strong> 150 MN and are considered as <strong>the</strong> largest state-<strong>of</strong>-<strong>the</strong>-art frontloading presses in <strong>the</strong> world. Typical applications for those presses for large pr<strong>of</strong>iles are among o<strong>the</strong>rs railway pr<strong>of</strong>iles. Looking at <strong>the</strong> market for railway pr<strong>of</strong>iles, it is clearly seen that it is a tight market with only few global p<strong>layer</strong>s, e. g. Constellium (formerly Alcan Engineered Products) or Aleris, but also some growing competitors from Far East like <strong>the</strong> Jilin Midas Group. The global distribution <strong>of</strong> <strong>aluminium</strong> railway applications shows regional differences: in North America <strong>the</strong> passenger transportation system is more or less limited to commuter service within <strong>the</strong> great metropolitan areas only, while in Europe in general <strong>the</strong> passenger volume is very high. On <strong>the</strong> o<strong>the</strong>r hand freight transportation by rail is very common in North America, whereas in Europe we have mainly freight transportation by road. For China, <strong>the</strong> most populous territorial state, passenger transportation by train is getting more and more important. All <strong>the</strong> fast developing countries like China, Russia, India or Brazil <strong>the</strong>se days do have infrastructural programmes which include new railway lines. These projects comprise high-speed lines for <strong>the</strong> long distance connections as well as investments in Intercity connections, commuter trains or metros. China’s aim is to build 20.000 km <strong>of</strong> high-speed tracks until 2020 while in Russia an investment programme <strong>of</strong> 7,5 billion euros for <strong>the</strong> erection <strong>of</strong> 11.000 km <strong>of</strong> high-speed rail tracks has started recently. Also India, which has <strong>the</strong> world’s largest railway network, is looking for fundamental modernization. Even in those projects where normally <strong>the</strong> big p<strong>layer</strong>s like Siemens, Bombardier or Alstom are in involved, <strong>the</strong>re is always a certain percentage <strong>of</strong> local content in <strong>the</strong> supplies, i. e. <strong>the</strong> <strong>aluminium</strong> extrusions are produced locally. This is one explanation for <strong>the</strong> big invest- View <strong>of</strong> <strong>the</strong> manipulator for loose dummy block handling and <strong>the</strong> 52,000-litre hydraulic tank ments in large extrusion presses in China. The International Union <strong>of</strong> Railways (UIC) is expecting that <strong>the</strong> global high-speed network will triple within <strong>the</strong> next 15 years. Taking into account that this is only an outlook on <strong>the</strong> high-speed network, a huge demand for railway extrusions is expected. Aluminium is not <strong>the</strong> only material railway cars can be built with. Steel is a permanent competitor. There are even some ideas to use composite material for certain areas <strong>of</strong> <strong>the</strong> car body. But <strong>the</strong> comparison between <strong>the</strong> integrated <strong>aluminium</strong> design and <strong>the</strong> steel structure design clearly shows a weight reduction <strong>of</strong> more than 20 percent on <strong>aluminium</strong> design. This is resulting in an estimated energy saving <strong>of</strong> five percent for every ten percent <strong>of</strong> weight reduction. The limited axle load <strong>of</strong> <strong>the</strong> European railway network only allows for higher pay loads if <strong>the</strong> net weight <strong>of</strong> <strong>the</strong> train is reduced. Additionally <strong>the</strong>re are o<strong>the</strong>r known advantages <strong>of</strong> <strong>aluminium</strong> like nearly 100 percent recyclability, good corrosion resistance, high strength to weight ratio or <strong>the</strong> decorative as- 34 ALUMINIUM · EAC CONGRESS 2011 Photos: SMS Meer
Counter platen with fixed tie rods EXTRUSION pect <strong>of</strong> <strong>aluminium</strong>. Looking at <strong>the</strong> global greenhouse gas emissions, 27 percent <strong>of</strong> <strong>the</strong>se emissions are caused by transportation and 73 percent are caused by road transportation, while only 2 percent arise due to rail transportation. Rail transportation is a ‘green solution’ to move people or goods and a low carbon technology. A slogan <strong>of</strong> <strong>the</strong> railway manufacturer Bombardier is pointing out, that ‘<strong>the</strong> climate is right for trains!’ Eventually all this leads to an increasing market for large pr<strong>of</strong>iles and since <strong>the</strong> numbers <strong>of</strong> operative heavy presses were limited, now big investments in extrusion plants for heavy duty and large sections are being made, especially in China. But it is not only <strong>the</strong> number <strong>of</strong> presses; it is also <strong>the</strong> size <strong>of</strong> <strong>the</strong> presses that is constantly increasing over <strong>the</strong> last years. While a 65 MN press was considered as a huge press a few years ago, today some people would call it ‘medium size’ only. Considering <strong>the</strong> recent orders <strong>of</strong> SMS… • 70 MN frontloading press for Nanshan Aluminium • 82 MN frontloading press for Nanshan Aluminium • 82 MN frontloading press for Yankuang Aluminium • 82 MN frontloading press for Nanshan USA • 100 MN frontloading press for Jilin Lijuan • 150 MN frontloading tube press for Yankuang Aluminium • 150 MN frontloading press for Nanshan Aluminium …we see a high potential on this market regarding also o<strong>the</strong>r press manufacturers from Europe or Asia who are getting significant orders on big presses, too. � ETS Extrusion Tooling Solutions ��
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