CAPITAL MARKET DAY, OCTOBER 6TH, 2015 ACHIEVEMENTS AND POTENTIALS IN LIGHTWEIGHT AND NON- AUTOMOTIVE APPLICATIONS Dr. Martin Habert 1
ACHIEVEMENTS AND POTENTIALS IN LIGHTWEIGHT AND NON-AUTOMOTIVE APPLICATIONS Division Hydraulic Non-automotive applications Lightweight automotive solutions SMI MAI 2015 ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 2
SCHULER GROUP STRUCTURE 6 DIVISIONS WITH GLOBAL RESPONSIBILITIES AUTOMOTIVE HYDRAULIC INDUSTRY SYSTEMS SERVICE AUTOMATION SMI MAI 2015 ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 3
HYDRAULIC DIVISION Facts and figures Technological and global market leader in hydraulic presses and forming systems History: Schuler, Müller-Weingarten, Hydrap Products: Hydraulic presses and complete systems for cold or hot metal forming, forging and composites production Applications: Automotive (ca. 55 %), Railway (ca. 25 %), Aerospace, Heat Exchangers, General industry Key Technologies: Hot Stamping Railway wheels Hydroforming Titanium Forming Fineblanking Hydraulic division 2015 Sales ca. 150 Mio. Order Entry ca. 160 Mio. Order Backlog ca. 170 Mio. Employees 165 Markets Europe ca. 30% Asia ca. 30% Americas ca. 30% Russia ca. 10% 1 12.10.2015 SCHULER CORPORATE PRESENTATION by 30.09.2013 4
TRADITIONAL APPLICATIONS HYDRAULIC PRESS LINE @ JAGUAR, 2001 5
WHAT REALLY COUNTS HYDRAULIC PRESS LINE @ TODAY Hydraulic presses:.very high press forces.at any position.as long as necessary 6
NON-AUTOMOTIVE APPLICATIONS 7
GROWTH MARKET RAILWAY Worldwide rail transport performance 2013-2023 [Index 100=2013] 160 140 120 100 80 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 12.10.2015 Freight rail Passenger rail Urban rail 100 = 10,711 billion tkm 100 = 3,536 billion pkm 100 = 448 billion pkm Source: SCI Verkehr 2014, Rail Transport Markets Global Market Trends 2014-2023 8
NON-AUTOMOTIVE APPLICATIONS RAILWAY SYSTEMS FOR RAILS SYSTEMS FOR WHEELS SYSTEMS FOR AXLES 9
SYSTEMS FOR WHEELS FORMING SEQUENCE Upsetting Preforming Rolling Dishing
SYSTEMS FOR WHEELS CLOSING THE GAP NEW SCHULER WHEEL ROLLING MACHINE
SYSTEMS FOR WHEELS COMPLETE FORGING LINE Customer Shandong Heli / China MH 10000 and 2x MH 5000 Wheel Rolling Machine MHRV 180/80 Tools Automation and Line Control 2012
NEW PRODUCTS CREATE NEW BUSINESS 4 CUSTOMER KARDEMIR, TURKEY 2013 Sawing lines for billets Furnaces (Andritz Metals) Hydraulic forging presses MH 10000 & MH 5000 Wheel roller MHRV 180/80 Dies Machining equipment (FFG) Automation, line control, auxiliary equipment 3 CUSTOMER SHANDONG HELI, CHINA 2011 Hydraulic forging presses MH 10000 & 2 x MH 5000 Wheel roller MHRV 180/80 Dies & automation & auxiliary equipment 11 5 I 52.500.000.- 1 2 CUSTOMER MWL, BRAZIL 2009 Hydraulic forging press MH 3000 CUSTOMER CAF, SPAIN 2007 Hydraulic forging presses MH 10000 & MH 5000 3 I 32.600.000.- 4 I 92.000.000.- NEW ORDER 2015 SCHULER & ANDRITZ METALS Hydraulic presses Wheel roller Dies, autom., aux. equipm Schuler: 36.500.000- Rotary furnace and heat treatment (Andritz Metals) Andritz: 16.000.000.- 1 I 9.200.000.- 2 I 3.200.000.- Order Intake Mio. 20xx 2007 2009 2011 2013 2015 12.10.2015 13
SCHULER AEROSPACE TITANIUM AND SPECIAL METALS HOT FORMING
HOT DEEP DRAWING 12.10.2015 SCHULER IN-HOUSE SHOW "AEROSPACE" JULY 1-2 2015 15
LIGHTWEIGHT AUTOMOTIVE SOLUTIONS SMI MAI 2015 ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 16
AUTOMOTIVE LIGHTWEIGHT DESIGN MOTIVATION LIGHT-DUTY VEHICLE STANDARDS ON CO 2 EMISSIONS Grams CO 2 per km, normalized to NEDC Liters per 100 km (gasoline equivalent) 220 200 180 9 8 160 140 120 100 80 60 40 20 0 EU 2021: 95 US 2025: 97 China 2020: 117 KSA 2020: 142 Canada 2025: 97 India 2021: 113 Japan 2020: 122 S. Korea 2020: 97 Mexico 2016: 145 Brazil 2017: 138 2000 2005 2010 2015 2020 2025 Historical performance Enacted targets Proposed targets or targets under study 7 6 5 4 3 2 1 12.10.2015 Source: ICCT 2014, Historical fleet CO 2 emissions performance and current or proposed light commercial vehicle/light truck standard:s 17
AUTOMOTIVE LIGHT WEIGHT DESIGN MOTIVATION INFLUENCE OF THE WEIGHT TO FUEL CONSUMPTION AND PERFORMANCE Rolling resistance R Gradient resistance: G Acceleration resistance A 12.10.2015 18
AUTOMOTIVE LIGHT WEIGHT DESIGN - MOTIVATION NETWEIGHT OF THE GOLF (1974-2013) 1600 1400 1200 1000 800 600 Netweight in kg Depending on model type and configuration 1 2 3 4 5 6 7 12.10.2015 Source: Volkswagen 19
AUTOMOTIVE LIGHT WEIGHT DESIGN CLEVER LIGHT WEIGHT DESIGN The multi-material body in white combines different components of light weight metals: High-strenght steels Cold and hotformed steels Aluminium Magnesium Carbon fiber reinforces plastics Less use of soft deep drawing steels Material mix increases the complexity in the joining technology THE DESIGN CONCEPT OF THE HYBRID CONSTRUCTION: The right material (depending on the function) at the right place in the smallest amount possible! 12.10.2015 20
AUTOMOTIVE LIGHT WEIGHT DESIGN SCHULER FORMING TECHNOLOGY FOR LIGHT WEIGHT MATERIALS HYDROFORMING PRESSHARDENING COMPOSITES 12.10.2015 21
HIGH-STRENGTH STEELS FOR AUTOMOTIVE HARDENING PROCESS IMPROVES TENSILE STRENGHT Hardening Steel qualities Elongation Tensile strenght SMI MAI 2015 ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 22
PRESS HARDENING WHAT HAPPENS WITH THE MATERIAL? USIBOR, 1500 MPA, ELONGATION<10%, STRUCTURAL PARTS Blanks are heated to 950 C in a furnace. The heating time of 5 minutes is important to achieve the proper material structure (austenite) The heated blank has to be fed into the press as fast as possible to avoid cooling of the material by air. The press has to close fast, form the part and keep it closed for several seconds. During this time the cooling circuits in the upper and lower dies are cooling the part down to approximately 200 C. Parts or Blanks Heating Forming and cooling down Austenite Perlite Martensite 12.10.2015 23
PRESS HARDENING TURN-KEY SOLUTIONS FROM SCHULER Competence center press hardening Schuler Hot Forming - dies, prototypes & process - hydraulic presses & entire process - automation for press hardening line - Line control & integration of furnace 14/05/2014 FORD VISIT 24
CURRENT SITUATION AND FUTURE NEEDS SIGNIFICANT INVESTMENTS FOR NEW LINES 350 300 250 Hot Stamping Part Production Million parts/year Forecast 2018: 500-600 Mill Today approx. 250 Mill. Trend upwards Number of hot forming parts per vehicle will increase from an average of 10 today to more than 30 in 2018 OEM experts say that by 2018 up to 600 Mio parts/year are needed End of 2014: ca. 240 lines in operation 200 150 100 50 3 Mill. 8 Mill. 1/3 OF INSTALLED BASE BY SCHULER 25-30 NEW LINES PER YEAR FOR THE NEXT 5-6 YEARS 0 1984 1988 1992 1996 2000 2004 2008 2012 2016 12.10.2015 25
NEW PRODUCT: HIGHEST PRODUCTIVITY AND ENERGY EFFICIENCY Stroke Rate OEE Strokes / year Energy per 1 Mio. Stroke Conventional others 3.6 SPM 60 % 1,000,000 1,500 MWh Press only! PCH flex with EHF 1-4 5.2 SPM 70 % 1,750,000 900 MWh Press only! Production time = 20 shifts/ week x 8h / shift x 50 weeks/ year = 8000 h/year 26
SCHULER TECHCENTER 2015 LOCATIONS Servo TechCenter Göppingen, D I MSD 250 Erfurt, D I TST 1.600, TSD 1.100 Tianjin, China I TST 1.600 Hot Stamping TechCenter Scope of Services Demonstration & Training Technology development Prototype production Back-up line for customers Göppingen, D I PCH-Linie Hydroforming TechCenter Canton, Mi USA I Hydroforming-Presse Automation TechCenter Gemmingen, D I Crossbar Roboter 4.0 Canton, Mi USA I Crossbar Roboter 4.0 Hessdorf, D I Intratrans 27
LASER BLANKING LINE SCHULER AUTOMATION 3 cutting heads Cleaning (class A) Processing from the coil Flexible stacking Continous feeding No tools
SOUTRAC WELDING LINE FOR HOT STAMPED DOOR RINGS ANDRITZ SOUTEC SMI MAI 2015 ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 29
THANK YOU! SMI MAI 2015 ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 30