Hydroforming in new dimensions Hydroforming in
Transcription
Hydroforming in new dimensions Hydroforming in
1 | 2014 fluid International news & information of the fischer group Hydroforming in new dimensions 12,000-tonne-press opens up a wide range of possibilities fischer Rohrtechnik: Laser welding and cutting in 3D fischer group: Constructive ideas for higher productivity fischer Mexicana: Third hydroforming press for Central America News Greeting New chapter Dear Business Partners, Dear Colleagues, Again and again we are treading new paths to offer our customers new and better solutions. It is not always clear when the time is right to focus on innovative technologies. In hydroforming we have accompanied the development of our subsidiary fischer Hydroforming and the experiences of other group companies for decades. Now we are opening a new chapter with the 12,000tonne-press. For some time now we have been able to further develop the hydroforming competence of the Editorial fischer group, in particular with thin-walled components for exhaust tracts. Thus, the hydro forming segment within the fischer group has grown steadily. In other segments of hydroforming this was not the case in the past. Yours sincerely, Now, however, we see the time is ripe to adapt to larger components and to prepare for further growth in hydroforming. It is another exciting chapter in the corporate history of the fischer group. Write history with us: with hydroforming in new dimensions. fischer China An additional 4,000 m² for the growth market New production and storage hall for the complete process chain Hans Fischer Founder and Chairman of the fischer group In China we are making steady progress. Now the next steps are planned, as fischer China has successfully established itself in both household appliances as well as in the automotive industry. Owing to specific customer orders, fischer China is building a new production and storage hall with an area of about 4,000 m². By the middle of 2014, this will provide space for hydroforming presses and enough room for new processing possibilities along the entire process chain: from perfect longitudinally welded pipes up to 80 mm diameter to bending, hydroforming, annealing and coating through to rinsing, cutting and final processing. “We also want to provide our customers in China with all the possibilities of world-class tube production and further processing, producing the same quality as in all the other plants of the fischer group,” says a determined Wolfgang Szymanek, Managing Director of fischer China. The manufacture of the new products will begin in September 2014. ‹‹ A worldwide network Title Theme fischer group: 12,000-tonne-press – hydroforming in new dimensions ........... 4 Dear Business Partners, Dear Colleagues, Secure and expand core competencies, and develop new abilities. This is how you could describe the current developments of the fischer group. In tube manufacturing and further processing, the fischer group shows that the progress continues even after more than 40 years. Thereby, increasingly complex assemblies are being manufactured. We report in detail about the new dimension of hydroforming in the fluid title story. At the same time, we consequently transfer our know-how, which we have acquired over decades, to our international subsidiaries. The result is a veritable fischer competence network with worldwide distribution. This also opens up ever new possibilities for you. Let us talk about which of our competencies can provide you with even more benefits. We certainly have plenty to offer you. Yours sincerely, Germany fischer Rohrtechnik: 3D laser welding and cutting expand the range of services .................................................................... 6 fischer Maschinentechnik – fischer Edelstahlrohre Constructive ideas for higher productivity .............................................. 7 Eco Talk fischer eco solutions: Fuel cell technology ............................................... 8 fischer eco solutions: ARU for the research vessel Sonne ......................... 8 fischer Canada: Long-term solar project .................................................. 9 Publisher: fischer group, Gewerbegebiet 7, 77855 Achern, Germany Editor: Dr. Michael Kühner (responsible) Hans-Peter Fischer Managing Director of the fischer group Contributors to this issue: Hans Fischer, Hans-Peter Fischer, Roland Fischer, Dr. Stefan Geißler, Thomas Gaiser, Frank Schneider, Thomas M. Prell, Christian Behrle, Daniel Hennig, Dr. Heinz Paar, Hans Wolfgang Szymanek, Erich Kotzenmacher, Konrad Fallert, Jochen Baurmeister, Alex Huber, Burkhard Schmidt, Thorsten Junge, Prof. Dr.-Ing. Bernd Engel, Jens Helmbrecht Contact: Tel. +49 7841 6803-0, E-mail: [email protected] International fischer South Africa: MIS makes productivity visible ............................ 10 fischer Tubtech: Third Hydroforming press arrives ............................... 11 fischer Canada: International anniversary celebration .......................... 17 fischer Austria: Export prize 2013 for global tubes – surpassing the standard ......................................................................... 17 Tech Talk fischer Hydroforming: Inconel – a new material in hydroforming ........ 12 fischer Austria: Vacuum-insulated tubes ............................................... 13 Science: All about tube bending, part 3: Feasibility assessment, determination of wall thickness ....................... 14 Team Talk fischer group Achern: The big fischer family celebration 2013 .............. 16 fischer Austria: 4th fischer dragon boat race broke all records ............... 18 fischer Germany: 2013 Mountain bike tour ........................................... 19 fischer Austria: The Austrian Rescue Dog Brigade (ÖRHB) guests in Griffen ..................................................................................... 19 fischer Germany: Federal Finance Minister Dr. Wolfgang Schäuble in Achern ................................................................................................ 20 Design: Frank & Konsorten Werbeagentur, Lahr, Germany Print: Straub Druck+Medien, Schramberg, Germany fluid 1 | 2014 // 2 Photo credits: fischer group, Jörg Wilhelm, Niklas Thiemann, fotolia fluid 1 | 2014 // 3 Titel Theme Hydroforming in new dimensions 12,000-tonne-press opens up new possibilities New possibilities on the large press But in the last few years, the overall market has again generally developed quicker. Various trends (see info box) speak for further expansion of hydroforming, even in the traditional hydroforming segments of the fischer group.“In the past, we were especially represented in the segment of 6-cylinder motors and upwards. For smaller engines the use of hydroforming was hardly conceivable. That is different today,” explains Sales Manager Burkhard Schmidt. Meanwhile, there are also applications for hydroforming in 4-cylinder engines, which, in connection with downsizing, characterizes an important development for fischer Hydroforming. Automotive structural components Tubing components in large format Heat engineering components for apparatus construction Hydroforming is a procedure which has already been used for decades for the manufacture of complex shapes from metal. The fischer group can look back on 40 years’ experience in this special processing technology, in particular, through the group company fischer Hydroforming at Menden. “We have developed more than 700 series components in hydroforming. Today, we have over 300 products in series production,” explains Dr. Stefan Geißler, the Managing Director of fischer Hydroforming. “And now we are laying the foundation for hydroforming in dimensions that are new at fischer!” This means the new 12,000-tonne-press. With a table size of 2.80 x 6.00 meters it opens up many possibilities for larger components or the simultaneous multiple tool usage. The new large press has been available since mid-December. During the construction of the new press, the entire press hall in Menden was also logistically optimized both for efficient serial production and for the transportation of larger components. Hydroforming – a forming process on the rise With the expansion of the hydroforming capacities, the fischer group is preparing for further growth in that area. So far, our company has specialized in medium-sized parts in the exhaust tract. “We were able to make full use of our experience with particularly thin-walled Sheet metal forming More rational production owing to multiple tool usage also with tubes with greater insert lengths and larger diameters, e. g. in the commercial vehicle sector Strategic hydroforming orientation in the fischer group Of course, the large press sets the mark. Thus, the fischer group can also provide all process variants for larger components in series production. The hydroforming specialists can develop rapid product and process innovations in all areas and put them into series production. And the fischer group is not only doing this in Germany but also, in the next step, with the expansion at the site in Mexico (see page 11) and with the new installation in Asia. At the Chinese location a complete process chain is being built: from tube production to bending, hydroforming, annealing and coating, through to rinsing, cutting and final processing. “We would like to be our customers’ first point of contact in all standard processes from tube production to forming, through to complex assemblies. As an excellent and high-quality technology, hydroforming is simply a must. That is why we use the technology, the know-how and our decades of experience – worldwide, wherever required by our customers,” says a confident and determined Hans-Peter Fischer. ‹‹ Trends in the use of hydroforming High demands concerning lightweight construction combined with high strength properties in the structural area in the automotive industry parts,” says Geißler concluding the development to the present time. In the 80s and 90s of the last century there was great enthusiasm regarding the use of hydroforming technology, particularly in the structural and bodywork sectors. On the other hand, the use of hydroforming in exhaust tract applications has steadily further developed. fischer Hydroforming was also duly involved. More stringent exhaust gas regulations for internal combustion engines in automobiles, but also for commercial vehicles, marine engines, stationary applications (heating technology, cogeneration plants, stationary engines, etc.), or construction machinery Optimized use of residual exhaust gas heat for greater energy efficiency during combustion Use of new materials with improved forming properties Let us implement your hydroforming ideas together! Talk to us about your ideas. We will put them into series production. Your fischer Hydroforming contact partner : Mr. Burkhard Schmidt Tel. +49(0) 2373-166-289 Fax +49(0) 2373-166-380 [email protected] and a high degree of strain hardening Globalized component manufacture, especially growth markets in the automotive sector fluid 1 | 2014 // 4 fluid 1 | 2014 // 5 Germany Germany fischer Rohrtechnik From a tube to a complex assembly 3D laser welding and cutting expand the range of services in further processing Over the years, the further processing of fischer tubes at fischer Rohrtechnik has been continuously developed. Today, the fischer group offers diverse possibilities in axial and radial forming; from hydroforming through to complex assemblies. The basis for this – besides the technological equipment – are especially the ongoing further qualifications of employees and the close cooperation with the development departments of our customers. Recently, it was a robot welding cell and a laser cutting machine, which opened up new dimensions in further processing at fischer Rohrtechnik. Now, components up to 6 kg can be automatically welded and spatial contours can be cut in three dimensions. “That may be, for example, parts from hydroforming, which are fluid 1 | 2014 // 6 functionally enhanced here,” says Frank Schneider, Production Manager at fischer Rohrtechnik, as he explains the new opportunities. processing, the economic production processes can then be precisely defined and implemented together. Working with economical efficiency at the location in Germany What can become of this collaboration can be seen in the current example of an exhaust system component for commercial vehicles. And this is just one of the many complex assemblies that are developed at fischer Rohrtechnik. This shows how serious the fischer group is about continuously developing their range of services. “We have shown time and again that it is still possible to manufacture complex components in an economical way at the location in Germany,” says a convinced Process Manager Alex Huber. However, as mentioned earlier, it is not only the technology that makes this possible. Also, the qualifications of the employees and the close and trusting contact with the customer are of particular importance. “The earlier we are involved in the development, the more efficient the solution will be,” says Alex Huber summarizing in simple terms. It is decisive that the course is set correctly at the beginning by first openly discussing all the technical possibilities and then working together to find the best solution. Thereby, the fischer specialists have a lot to contribute: all forming processes, sawing, chipless cutting, hydroforming – and now also 3D welding and cutting. On the basis of suitable ‹‹ fischer Maschinentechnik – fischer Edelstahlrohre Constructive ideas for higher productivity A new tube profiling system with a powerful multi-head saw In the design and construction of tube profiling systems, fischer Edelstahlrohre has always relied on the imaginative expertise of its sister company fischer Maschinentechnik. The direct collaboration is one of the strategic success factors of the fischer group. Or, as the Production Manager of fischer Edelstahlrohre, Thomas Gaiser, puts it: “We rely on fischer Maschinentechnik because they provide us with the best quality and maximum flexibility with respect to subsequent customizations and service. Through the close cooperation, even our short-term desires can still be included in the mechanical engineering.” In any case, the demands on a modern machine concept for the production of high quality stainless steel tubes are remarkable. Through the many years’ experience in tube welding, the machine construction is constantly optimized. After all, the machines must endure a great deal in the many years of a three-shift operation. Only a rugged construction made entirely from top quality components can withstand this. New tube profiling system for tubes in 30 to 80 mm diameter The new machine is mainly used to increase the tube welding capacity in the range of 30 - 80 mm in diameter, because there is a growing demand of “larger” diameters in the automotive sector. The aim was at developing a system exclusively for automotive parts, mainly components for exhaust systems. Thereby, the cycle time per part was also to be significantly reduced. The clever idea for this: Through the direct integration of a multi-head saw, the finished product is created “in line”, i. e. in time with the pipe welding. In order to further reduce downtime, the improvement of serviceability was also one of the constructive objectives. fischer-group-founders and Managing Director of fischer Machinentechnik.“Not only do we develop the machines, we also ensure the correct installation on site. And this is the case in all fischer companies worldwide.” The new tube profiling system is the most recent example of this special success story. Owing to the new constructive ideas, particularly with the integration of the multi-head saw, fischer Edelstahlrohre is once again at the forefront of development. ‹‹ The timing for the new tube profiling system 03 / 2013 – Start of project Owing to decades of specialization and the experienced assembly team of fischer Maschinentechnik, we were able to consider all the wishes of the stainless steel tube producers. “We have mastered each matter to the last detail. This results in the particularly high product quality with which the fischer tubes have achieved a worldwide reputation,” says a convinced Roland Fischer, one of the sons of the 12 / 2013 – Completion at fischer Maschinentechnik 12 / 2013 – Assembly and test at fischer Edelstahlrohre Achern 01 / 2014 – Start of production on the new tube profiling system fluid 1 | 2014 // 7 Eco Talk Eco Talk fischer eco solutions fischer Canada Fuel cell technology Long-term solar project New commitment to renewable energies Working together for more renewable energies In addition to the successful implementation of projects in the areas of solar thermal desalination and absorption refrigeration units, fischer eco solutions has been doing in depth development of systems for the provision of electrical and thermal energy already for the last two years. In 2011, the fischer group acquired the majority shares of the company SerEnergy A/S, based in northern Denmark. The stated goal is to maintain and develop the research and development of the so-called high-temperature PEM fuel cells at this location. Simply clean energy: A fuel cell converts the chemical reaction energy from continually supplied fuel and oxygen into electrical and thermal power. Methanol or natural gas is typically used as a fuel, which is converted into hydrogen in a so-called reforming process. The application areas for fuel cell technology are diverse but can be found particularly wherever the power supply of autonomous electrical systems are concerned, such as in vehicles or mobile phone base stations. New contact person: Dr. Jochen Baurmeister Contact persons for the field of fuel cells at fischer eco solutions are the Managing Director Christian Behrle und Dr. Jochen Baurmeister. After his studies, Baurmeister, born in 1964 in Kiel, started working in chemical engineering. He has led several fuel cell projects since 1997. Dr. Baurmeisterhas been employed at SerEnergy A/S since the year 2011. There, he is responsible for transferring the fuel cell know-how to Achern and for the build-up of production at fischer eco solutions. In his function as a member of the Supervisory Board at SerEnergy he acts as a link between the two companies in Germany and Denmark. ‹‹ This business became possible through the merger of local building owners. And there is a joint investment in a large project rather than organizing several small ones. Thus, the technical equipment was unified, costs were reduced and experience was shared. fischer eco solutions Waste heat cools the vessel “Sonne” ARU for the new construction of the famous research vessel Cooling with heat is the principle of absorption refrigeration units. This also works in rough sea climate. Therefore, in the newly built research vessel “Sonne” the waste heat from the diesel engines will be used for cooling. ment of the system itself are trimmed for offshore suitability. Thus, the proven fischer stainless steel tubes, with the necessary corrosion resistance for seawater application, provide the re-cooling. fischer eco solutions is dedicated to the research and development of this cooling process and has developed several of its own absorption refrigeration units (ARUs). They cover a range from 20 kilowatts to 1 megawatt of cooling capacity. The system was also tested through its paces on a special pivot table. In this way, the fischer absorption refrigeration units are tested under realistic conditions. Rolling, pitching and listing on the high seas can all be overcome by the absorption refrigeration units from fischer eco solutions, without loss of cooling capacity. After more than two years’ preparation, fischer Canada has secured a 20-year contract for the sale of solar energy to the public grid at more than five times the current electricity price. The contract was concluded with Ontario Power Authority (OPA). It guarantees remuneration as part of an intergovernmental agreement for the promotion of renewable energy and for the creation of jobs in the province. This is not only a profitable business, but also documents fischer Canada’s commitment for the lowest possible environmental pollution. At the same time, the policy of retreating from atom and coal power is supported in Ontario. “An ideal win-win-win situation – for business, politics and the environment,” says an enthusiastic fischer Canada Managing Director, Tom Prell. fischer Canada at McMurray Road: The solar power plant will be installed here. 900 panels for 237 kW fluid 1 | 2014 // 8 As of 2014 one of the systems from fischer eco solutions will also travel on board the new ‹‹ Optimally oriented: This is how fischer Canada harvests solar energy. 90 75 The latest specialties are the absorption refrigeration units (ARUs) on the high seas. Both the choice of materials as well as the develop- After a careful selection, fischer Canada chose the building at 620 McMurray Road, to be equipped with about 900 solar panels. Currently, planners and craftsmen are being selected who can take the lead during the installation of the solar plant. The assembly is due to begin in spring 2014. And everyone is curious as to when the first current will flow. fischer Canada’s solar plant is designed for up to 237 kW DC and is equipped with the latest technology. A large part of the planning was used for comparing various plant concepts, in particular, different inverter technologies. In the end, decentralized string inverters were most convincing. Shading loss: Shading loss: Shading loss: Shading loss: Shading loss: Sun height [°] 60 The research vessel "Sonne" 12h 13h 11h 14h 9h 45 22 June 22 May - 23 July 20 Apr - 23 Sep 20 Mar - 23 Sep 21 Feb - 23 Oct 19 Jan - 22 Nov 22 December 15h 16h 8h 15 17h 7h East South Attenuation for diffuse: 0.023 and albedo: 0.847 10h 30 German research vessel “Sonne”, which is currently being built at the Meyer Werft at Papenburg. “It’s a special honor to be involved in such a challenging project,” says a very pleased company founder Hans Fischer. 1% 5% 10 % 20 % 40 % 18h 6h 19h 0 -120 -90 Behind the Plane -60 -30 0 Azimuth [°] 30 60 90 120 Behind the Plane ‹‹ fluid 1 | 2014 // 9 International fischer South Africa fischer Tubtech MIS makes productivity visible Third hydroforming press arrives In a new process organization era since January 2013 Modernized 1,500 ton machine will be transferred to Central America shortly Everything at a glance with the new management information system In mid-2012 fischer South Africa tackled the introduction of a new management information system (MIS) from the South African Shopware company. The visual management system simplifies processes by helping employees record and visualize their current job performance at their workplace. At the same time it facilitates reporting by making critical points visible and displaying current as well as past machine performance. The System uses an Overall Equipment Effectiveness (OEE) approach to make visible obstables relating to downtimes, speed, and quality. The information is collected in real time and is available company-wide. Costly collection and analysis of information has been dispensed with almost completely since current data is available in real time. Thus, incidents that require fast interventions can be rectified immediately. Recurring problems are solved and the way is paved for a team-oriented workplace. fischer South Africa has the Shopware system at the most important bottlenecks – those places where all subsequent processes are dependent on the results of these machines. A great deal of effort went into taking into account and integrating everything that was necessary. In use since January After an extensive test phase, the Shopware system has been in productive use since January. It has proved to be very fruitful both in morning production meetings and for internal competition among machine operators. Downtimes have been significantly reduced and the continuous monitoring has led to eliminating basic mistakes and increasing total productivity. The goals of MIS at fischer South Africa: Visualizing Overall Equipment Effectiveness (OEE) in real time. A company-wide culture of finding solutions and making continuous improvements. Automatic importing of orders of the current inventory management into the MIS display in the machine operator’s Person Machine Interface (PMI); order selection, implementation, and completion. Idenifying, eliminating, or minimizing production breakdowns and downtimes. Monitoring of speed, utilized as opposed to available productivity time, and quality on every machine. Providing a system that enables managers to respond to all issues. fluid 1 | 2014 // 10 “Today everyone can see within two minutes on the LCD monitors on the production floor just how his or her machine is running – and has been running for the past seven days,” Erich Kotzenmacher, Managing Director of fischer South Africa is happy to say. “We have made a great leap forward with the MIS in meeting LEAN production requirements and opening up competitive advantages.” ‹‹ These Shopware modules are in use at fischer South Africa The Person Machine Interface (PMI) controls the functioning of every machine and is the heart of the system. The management information system (MIS) provides detailed reporting in graphic form and enables fast intervention when necesary. Customer satisfaction is not just a word at the fischer group. The current relocation of a hydroforming press from Menden to Mexico is evidence of it – and in record time! A customer decided in July 2013 to relocate a project to Mexico from its location in Germany. The associated hydroforming components that among others had until then been produced in Germany were therefore to be manufactured in Mexico as well. Immediately, fischer Hydroforming, fischer Rohrtechnik and the colleagues from fischer Mexicana committed themselves to this assignment and were able to present a customeroriented solution as quickly as possible. With success! The fischer group was awarded the contract. “We are underscoring with this our claim to be a very flexible, global solutions partner for our customers,” Hans-Peter Fischer, Managing Director of the fischer group, is happy to say. There is a total of 8 high-end components that add up to a total number of 1.6 million parts per year. In order to guarantee the customer this number of parts and to be prepared for future growth in the hydroforming area in North America, the fischer group decided to Challenging timing Beginning of July 2013 .............. Project decision from customer July 19, 2013 .............................. Oral commissioning of the retrofit with Maschinenbauer Dunkes Until mid-December 2013 ........ Overhaul of the press Starting December 2013 ........... Interim production of the components at fischer Rohrtechnik End of December 2013 .............. Testing of the press with tools Until end of April 2014 .............. Shipment, customs clearance, conveyance, installation, startup Subsequently ............................ Beginning of mass production in Mexico install a third hydroforming press in Mexico. With this milestone, the position of the Central American location has once again been considerably strengthened. Hydroforming parts have been manufactured since 2003 at fischer Mexicana. That was already a significant milesone: Mexico was the first hydroforming location for the fischer group outside Germany. Fast move with strategic significance In order to keep to the tight scheduling, an existing 1,500 ton press from fischer Hydro forming Menden underwent a radical retrofit, at the end of which the hydrofitting machine will be universally deployable with the most up-to-date technology and an increased builtin height for all tools in Mexico. This will raise the operational readiness and flexibility for hydro forming production for the North Americanmarket as a whole. “The relocation of the press is both very important for the current project and a strategic decision,” explains Horst Wiesenberger, ManagingDirector of fischer Mexicana. “Everything is pointing to an increase in demand for more complex forming parts. With the third hydroforming press, we will be optimally prepared for further growth in this area.“ ‹‹ The Yield/Quality module enables customer-specific quality standards to be taken into account in production. The Asset Care module lists all of fischer South Africa’s machines and forms the basis for a maintenance management system that organizes everything – from changing a light bulb to complete machine breakdown. The PDCA (Plan Do Check Act) module provides a work environment for continual process optimization. fluid 1 | 2014 // 11 Tech Talk Tech Talk fischer Hydroforming fischer Austria A new material in hydroforming Vacuum-insulated pipes How an automobile high performance manifold made out of Inconel came into being Project VIP should drastically reduce energy costs As part of its development of an automobile high performance manifold, one of the world’s leading manufacturers of exhaust systems approached fischer Hydroforming about producing manifold components from a nickel-based alloy using the hydroforming process. The material guarantees mechanical stability and corrosion resistance even at the highest temperatures. fischer Hydroforming was happy to accept this assignment and to bring it to mass production readiness. The high grade material can thus be used for the first time in the production of demanding exhaust system components for high-end automobiles. The integration of a new material into the production environment is a special challenge. “You have to plan precisely and work very carefully to get in the end a practical solution that is economical at the same time,” is how Dr. Stefan Geißler, Managing Director of fischer Hydroforming, describes the ambitious task. The development team from Menden could fall back on years of practical experience in aerospace. That was already a good foundation. Yet further basic studies were made. Together with the University of Siegen, the material data were explored and forming limit diagrams were created as the basis for the hydroforming simulation. This was followed by practical testing and comparison with theory using test tools. When that was successful, it became a matter of implementing the ambitious process engineering. An important milestone was the strain hardening of the material during the forming to meet the shaping requirements. New as well were the experiences with the stability and wear on the tools. fluid 1 | 2014 // 12 Step by step – from idea to mass production Feasibility study ZSB/Assembly production FEM simulation Mass production Hydroforming component development/design Prototypes/ pre-production runs Process development Tool construction Fresh challenges “When we were all very happy to have brought the Incontel parts into the desired shape, a special challenge awaited us,” remembers Thorsten Junge, the Development Manager. What he meant was the separation technology: how can the high strength material be processed economically? In the end there were different technologies that, depending on Tool design the component, made it to the top: both sawing as well as laser and power cutting are used in mass production. After all the practical hurdles were cleared, the new material and associated process could be integrated into quotes and projections. The customer’s first series projects could begin! “That was a nice challenge for us, for which we are very grateful to our customer. We are also a little proud of the great collaboration of different specialists with the materials researchers at the University of Siegen. That simply shows you what the company culture is made of,” Dr. Stefan Geißler is pleased to say about the joint success. ‹‹ The efficient handling of energy resources is becoming an increasingly critical success factor in industrialized countries. fischer Edelstahlrohre Austria is working on a solution for minimizing heat losses for superheated steampipes or cryogenic applications. In addition to saving energy, the vacuum-insulated pipe systems can be built and cleaned more simply. The VIP (Vacuum-Insulated Pipe) project began in 2011 and is now entering the pilot phase after completing the scoping phase. The goal of this development stage is the technical measurement of the savings potentials and their economic assessment. In principle, it is a matter of producing a double-walled stainless steel pipe with vacuum insulation. Besides developing and maintaining a stable high vacuum, the big challenges are mechanical stresses, for example during pressure changes. The first trials under laboratory conditions with the development partner alvatec were promising and confirmed the high-vacuum-suitable quality of the tube processing at fischer Austria. Successful university cooperation The first prototypes along with the measurement setup were chiefly developed and constructed by the project coordinator of fischer Edelstahlrohre Austria, Adnan Vedinlic, in collaboration with the University of Mittweida. In the pilot plant that has now been built, insulation models are being tested and compared with regard to their heat transmittance. It is expected that the VIP model will save enough energy primarily at high and very low media temperatures to amortize significantly the higher investement costs. planned is a trial installation at an Austrian brewery and at a local food processor. A first industrial application is expected in 2014. “Everything has worked wonderfully up to now. I’m very optimistic that the idea will also prove its worth in practice,” project director Adnan Vedinlic is convinced. ‹‹ A wide range of applications The application areas would be wide-ranging – from power plant engineering to the food and paper industries. Cur rently 3D illustration of the pilot plant for measuring pipe insulation. Complex connections and secondary form elements can also be implemented with Inconel. fluid 1 | 2014 // 13 Tech Talk The bending task is given as the bending factor B: as “true” elongations and are abbreviated with the symbol ϕ and from and the technical elongation ε they can be derived as follows: Science For all bends which have the same bending factor, the stresses of the semi-finished product are the same. This means, for example, that halving the bending radius R and the external diameter of the tube results in identical conditions. This can be clearly seen through the elongation, which can be calculated as follows: All about tube bending Part 3: Feasibility assessment, determination of wall thickness Prof. Dr.-Ing. Bernd Engel Chair for Forming Technology at the University of Siegen A practice-oriented view by Prof. Dr.-Ing. Bernd Engel Therefore, it only depends on the bending ratio. Born in 1962 High school graduation at Winfriedschule, Fulda Study of Mechanical Engineering at the Technical University of Darmstadt “All about tube bending” in four parts Doctorate in Hydroforming at University of Darmstadt The aim of the series is at providing the reader with guidelines for laying out a bending process. In addition to the necessary calculations of the bending forces, in subsequent chapters information is given on the use of the individual axis on the bending machine for the optimization of the bending process. Thereby, a feasibility study can also be carried out for untypical materials. In the last part, guidance is given on performance and design of tool elements (wiper die, mandrel, counter holder and clamping tools). If you apply the bending task to rotary draw bending, then this strain distribution can be calculated as a function of the bending radius and a variable y (Figure 1). Chairman of TIME GmbH 0.6 re l 0.5 No Sp man oo dre nl typ em an d Bending factor B [-] 3.50 Risk of cracking Thereby, the relation is to the neutral line (∙R). At the distance y (positive to the outside) the corresponding elongation or compression is derived from geometry. Bending diagram 4.00 3.00 Main elongation ϕ1 Chairman of VDI Technical Committee “bending technology” k lin ,1 rel nd a m pe l-ty Bal links everal andrel, s Ball-type m 2.50 2.00 1.50 1.00 0.00 The largest or smallest elongation is therefore the following: 0 10 20 30 40 50 60 y rc Figure 1: Idealized bending arc during a rotary draw bending Limit of the constriction σ σ 0.2 σ 1 2 σ σ σ 2 1 0.0 -0.4 1 2 σ Sliding counterholder 2 σ Rotating counterholder 1 σ "Breaking" counterholder σ 1 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 Main elongation ϕ2 Risk of creasing In the picture are two bends with similar bending factor and very different wall thickness factors. Basically, the bending task is more difficult in the bottom right. This empirical graph only gives a recommendation for choosing the type of mandrel. In principle, a wiper die is recommended if a mandrel is required. The chart does not consider cracking or changes in wall thickness. R Inne ra Elongation at break 0.3 1 Figure 2: Bending diagram with a recommendation for which mandrel to use Outer arc 0.4 0.1 0.50 Wall thickness factor W [-] In order to compare bending tasks, dimensionless parameters are introducedin rotary draw bending. fluid 1 | 2014 // 14 With these two factors the bending task can be depicted in the bending diagram. The bending diagram describes the bending task by showing the bending factor and the wall thickness factor (see Figure 2). Via the estimated elongation during tube bending, as it has been derived in this part, a statement can now be made on the longitudinal elongation. The traverse elongation is not taken into account. In the same manner, when estimating the elongation there are no differences via the arc length. Actually, the elongation progression is also measured via the length. Thereby, the elongation increases over the bending angle and reaches a maximum value at approximately half the angle before it decreases again towards the end of the arc. The estimation provides the maximum value in longitudinal direction. In the diagram, the expected elongation of the bending task (B=1) is marked on the yellow path. When actually measured, the longitudinal and lateral elongations are on the red path. It can be seen that the estimation predicts slightly higher values. A curve can be defined for each material depicting when the material will fail, as in Figure 3. Founder and spokesperson for “expert workshop bending” ) For rough calculations, it is sufficient to calculate with the symmetric stress pattern. Chair for forming technology ε(y Bending elongation, bending factor, wall thickness factor Bending stresses lead to a typical strain distribution over the cross section of the tube. It is known that a near linear distribution of max strains on the outer arc leads to compressions of the inner arc. Appointed professor at the University of Siegen y The first part explained how the required bending moment can be determined for a bending task. On this basis, the size (starting torque) of the required bending machine can be calculated. In addition to the geometrical conditions, the torque requirement must be adjusted according to the range of the machine. Factors influencing the bending moment are material type, diameter, bending ratio and wall thickness. The second part aimed at the geometrical representation of bending components. The calculation formulas were shown, with which a calculation of the bending isometry and the conversion to machine data is carried out. Another dimensionless parameter describes the thickness of the walls, represented by the wall thickness factor: Thus, the elongations that were measured on all grid points can be depicted in a deformation diagram as longitudinal elongation (ϕ1) and as lateral elongation (ϕ2) (Figure 3). Grid analysis, transverse strain, strain path The so-called strain analysis has proven useful for the description and direct measurement of strain during forming. Hereby, a grid is electrolytically applied to the semi-finished product. The spacing of the grid points are defined and are changed after forming according to the elongation that has taken place. After forming, the grid points can be read with a camera system and by putting them into relation with the starting grid, the elongation can be determined. For each grid, there are two main elongations on the surface of the tube. Therefore, the longitudinal and lateral elongation can be determined from one point. These elongations are described Figure 3: Illustration of the forming limit diagram Using this curve, and the knowledge of transverse elongation, now an estimation can be made whether a bend without cracking is possible or not. The lateral elongation is essentially influenced by the counterholder or, to a much higher degree, by the boost. If you take a look at the forming limit curves, then the minimum possible elongation at ϕ2=0 which is exactly the logarithmic uniform elongation from the tensile test. You can therefore assume that upon undercutting this limit the bend is in any case possible. The basic feasibility can be assessed with the condition: fluid 1 | 2014 // 15 Team Talk International fischer Canada International anniversary celebration With more than 380 guests from around the world Hans Fischer with both of his sons and their families, and the subsidiary Managing Directors of the fischer group companies from Germany, South Africa, China, Austria, and the USA. fischer group Achern Look what your parents are making The big fischer family celebration of 2013 Following 2002 and 2005, the fischer group’s third family celebration took place on July 6, 2013 in Achern-Fautenbach. Under brilliant sunshine, a total of 1,500 employees and their families accepted the invitation. In extensive guided tours, everyone could discover what mom and dad are making at the fischer group. Two hours went by quickly if you wanted tion received as a gift specially designed fischer T-shirts with the slogan “You are our future.” “This is only a small indication to remember how important it is to show children our indispensable appreciation of them,” said Hans Fischer. The catering by the Seebach ski club and music association was hearty. Full use was made of the wide range of offerings – especially for the children. And company founder Hans Fischer had a special surprise in store for the youngest generation. The new genera- The family day provided all kinds of fun and happy faces. One could hardly better sum up the fischer group’s familial and human character. ‹‹ Hans Fischer sends a signal with the red fischer T-shirts: “You are our future.” We would also like to take this opportunity to congratulate the team from fischer Canada for their great work! ‹‹ fischer Austria Outstanding Performance from Austria Export prize 2013 for worldwide tubes that surpass the standards to see everything that fischer Edelstahlrohre, fischer Rohrtechnik, fischerMaschinentechnik and fischer eco solutions have to offer. fluid 1 | 2014 // 16 On September 12th, fischer Canada celebrated its 25th company anniversary at its plant in Waterloo, Ontario. Invited in equal numbers were local dignitaries, suppliers, customers, and employees. More than 380 guests from around the world accepted the invitation. On hand were company founder Guests were greeted with a glass of champagne around 3 pm. This was followed by a guided tour of the company, hors d’oeuvres, and a social get-together. Beginning at 7 pm, there were several speeches by the mayor of Waterloo and the vice-mayor of Kitchener, among others. Hans-Peter Fischer congratulated the Canadian team on its 25-year history of success and presented Uta Prell, Tom Prell as well as Kim Lizun certificates for 25 years of service. In perfect weather, the subsequent celebration lasted well into the night – accompanied by the Robin Reid Music Quartet and hypnotist Dr. Mike Mandel. The Carinthia Chamber of Commerce again this year awarded its coveted trophy for outstanding export performance as part of its export gala. fischer Edelstahlrohre Austria could prevail this time in the category of mid-sized businesses after succeeding in reaching the finals of the best three companies in 2012. The winners of the 2013 Carinthia Export Prize. Assessed were both the percentage of exports, which amounts to over 96% at fischer Austria, as well as the distribution of markets within and outside of Europe. Markets in Asia and North America could be opened up through customer-oriented adaptation of product parameters, combined with intelligent logistical planning. Premium quality that has been made visible in processability, longer service life or other customer benefits is not only in demand in Europe. Tubes from fischer Austria thus cool high-performance electronics in China and facilitate oil production from oil sands in Canada. Annealed drinking water tubes in the USA come from Austria just like tubes for grappling with natural gas liquification in India. Common to all these applications are that they place demands on the tubes that go far beyond the usual tube standards. ‹‹ fluid 1 | 2014 // 17 Team Talk Team Talk fischer Germany 2013 Mountain bike tour Summertime mountain biking with a private stopover This year the fischer mountain bike weekend took to the trails during splendid weather with international participation. 4 women and 44 men tackled the total of around 3,700 meters elevation difference (ME) – among them, five employees from fischer Austria, including the Austrian Managing Director, Heinz Paar. They covered an additional round trip of around 1,600 km aside from the tours on bike. fischer Austria Stroke for stroke 4th fischer dragon boat race breaks all records The hard-stroking competition in the long boats took place on September 6, 2013 – an event by now for around 500 active participants and 2,000 spectators and guests. What most people don’t know is that it’s not just for fun but for location marketing as well. Due to high out-migration trends, the ‘Battle for Contractors and suppliers representatives form an honor guard. Talents’ is raging in Carinthia. But where others attract young workers with advertisements and flyers, fischer Austria wanted to go another route.Thus originated the first dragon boat race for employees. “We wanted to present ourselves primarily as a regionally committed and attractive employer,” stresses fischer Austria Managing Director, Dr. Heinz Paar. “Then it went stroke for stroke.” Today the fischer dragon boat race sends a socially committed signal to the region and provides fischerAus tria with national attention through resonance in the media – also for interested new talents. 2013 – Premiere on Lake Pirkdorf 16 teams from the fischer group and affiliated companies competed last year and brought the waters of Lake Pirkdorf to a boil. In brilliant sunshine, the amusement park, Segway course, and other attractions could be used at no cost. Those up for it took the slow train on the grounds or visited the team camp, which was more than 200 meters long with 25 tents. For the first time as a guest this year was the owner of the fischer group, Hans Fischer with his wife Brunhilde. Their attendance motivated the fischer teams in particular: “Black Forest Marie” from fischer Germany in Achern, the 2012 title defender, the team “Formers 007 – License for Forming” from fischer Hydroforming in Chemnitz as newcomers, and the host team, “Ylvi and the Strong Men” from fischerAustria. However, the “SOBs,” a joint team of the Kruschitz Recycling and Goyer Hans and Brunhilde Fischer (middle of the picture) display their enthusiasm. Abfallentsorgung companies, were a few strokes faster and secured the 2013 challenge cup. In addition to the race, the costume awards have developed into a special highlight. The costumes this year could hardly be surpassed for their inventiveness. A fantastic atmosphere prevailed to the evening awards ceremony and the closing fireworks and made the 2013 dragon boat race a top-class event. Following tradition, on Saturday evening there was a barbecue at the Kappler ski lodge. The Fischer family also attended, thereby supporting the tour not only financially. „On behalf of the active bikers, I would like to sincerely thank the Fischers,” co-organizer Frank Schneider happily declared about the gregariousness of the entrepreneurial family. “That simply goes to show how much of a family it still is at fischer.” ‹‹ ‹‹ fischer Austria Rescue dogs on the crane The Austrian Rescue Dog Brigade (ÖRHB) guests in Griffen EVA GmbH – a reliable partner of the event over the years. Thank you for your hard-stroking support We thank all the teams for their participation, the sponsors for their support, visitors for contributing to the festive mood, guests of our customers, and the couple Hans und Brunhilde Fischer for their congenial attendance. Special thanks go to the many helpers and the maintenance team – Markus Köstinger, Markus Vallant, Benedikt Zwitkovitz, Manfred Lesiak, Bruno Fischer, Bernhard Brand and Angelika Scharf, who supported this event outside of work to an outstanding extent and were a major part of its success . Further information at: www.fischer-drachenboot.at fluid 1 | 2014 // 18 A choice of three tours of between 40 and 85 km plus 100 and 1,900 ME was available on Saturday. So there was something for every biker. The “challenging recuperation” over 30 km and 700 ME followed on Sunday. In addition to the sporting aspect, conviviality was again a top priority. fischer colleague Kosmas Wunsch got especially involved. He organized a stopover at his house and invited the fischer bikers for drinks and pretzels. ‹‹ The Austrian Rescue Dog Brigade (ÖRHB) has to be available around the clock all year to res cue people in case of emergency. Regular training under challenging conditions is necessary so that everything works at the crucial time. The rescue brigade found these conditions also at fischer Edelstahlrohre Austria. The rescuers could carry out a demanding ground exercise on the premises and in the warehouse area of the production floor. Important assignments were able to be practiced realistically and improved with the unique opportunities of a flight simulation. After a theoretical section on techniques for roping up, rescue practice was performed in the fit-corner (fischer information & training center) on the 7 ton double overhead crane of the finished product warehouse. Flying like in a helicopter Since flying in a helicopter – both in the cockpit as well as outside hanging on the cable winch – is part of the training, the dedicated dog handlers/dog teams became familiar with this discipline by means of flight simulation on the indoor crane. Beginners and experienced teams were at this realistic training, during which the buckling up and strapping in of handlers and dogs could calmly be practiced – a unique and unforgettable scenario that provided precious memories. ‹‹ “The ÖRHB sincerely thanks the team of fischer Edelstahlrohre Austria GmbH for its exemplary hospitality, which substantially contributed to making volunteer work possible in difficult times.” fluid 1 | 2014 // 19 Team Talk fischer Germany Federal Finance Minister in Achern 50th anniversary of the CDU Economic Council with Dr. Wolfgang Schäuble Training and advanced vocational qualifications 2013 fischer Maschinentechnik Florian Lorenz, Technician, May 2013 Bastian Huber, Industrial Master Craftsman in Metal, June 2013 Bernd Waltersbacher, Industrial Mechanic, June 2013 fischer Edelstahlrohre Dirk Klüter, Industrial Mechanic, March 2013 Thomas Waltersbacher, Industrial Master Craftsman in Metal, June 2013 Corinna Kern, Industrial Clerk, July 2013 Daniel Wonsik, International Welding Specialist, July 2013 From left to right: Konrad Walter, Section Spokesman Baden-Baden/Rastatt; Markus Arendt, Section Spokesman Ortenau; Dr. Wolfgang Schäuble, German Finance Minister, Hans-Peter Fischer, Managing Director of the fischer group On June 28, 2013, the fischer group welcomed a prominent visitor. At the invitation of the sections Ortenau, Baden-Baden/Ra statt and Karlsruhe/Bruchsal in the national association of the CDU Economic Council, the German Finance Minister travelled to Achern. In front of 100 invited guests and many interested employees of the fischer group, he gave a speech for the “Financial and Fiscal Policy Expert Discussion North Baden” in the modern ambiance of the new multifunctional fischer-canteen. Thereby, and in the subsequent discussion, the participants were able to learn at first-hand which financial and fiscal policy challenges await the medium-sized enterprises in Germany. The broad range of topics covered debates about public finances, possible tax increases, the design of the European fiscal policy and rules of the international financial markets. “We are very pleased that Dr. Wolfgang Schäuble and the Economic Council of the CDU were our guests,” said fischer’s Managing Director, Hans-Peter Fischer. “We were able to show that we are not only good hosts and able to give our fellow entrepreneurs a few insights into our company. But it was also an expression of our economic policy commitment in favor fischer Rohrtechnik Thomas Doll, Industrial Master Craftsman in Metal, July 2013 Georg Frank, Industrial Master Craftsman in Metal, July 2013 Daniel Huber, Industrial Master Craftsman in Metal, November 2013 F.E.R. fischer Edelstahlrohre Irene Sester, Certified Human Resources Specialist, January 2013 We would like to congratulate the graduates! of the small and medium-sized enterprises in general.” Dr. Schäuble was impressed by the constructive speeches and the all-round successful event. ‹‹ Stay informed under: www.fischer-group.com