Skills

PRECISION AND RELIABILITY FROM THE VERY BEGINING

Our customers place demands on our skills on a daily basis. This particularly applies to the constantly new development of highly-stressed components. Schmiedetechnik Plettenberg optimises your components through a consistent application of CAD/CAM technology and makes its expertise in development and manufacturing available to the benefit of its customers.

The latest simulation tools support and secure component and process development from the idea stage up to a ready-to-install solution. We will be happy to demonstrate the working of our developments through FEM calculations or fatigue strength tests. Schmiedetechnik Plettenberg manufactures with its experience gained from a long-standing tradition of producing high-precision components and specialising in gears and engines.


PROCESS DEVELOPMENT

As a development and systems partner in the automotive sector both over many years (OEM, TIER 1, TIER 2) and for non-automotive partners, we support our customers on the path from the initial design to a ready-to-install product. Flexibly deployable CAD workplaces put us in a position to be able to generate and implement solutions together with our customers. Extremely difficult geometric forms in our components are perfectly generated within little time using the latest CAD/CAM and simulation processes.

One of our strengths is the re-design of geometric forms leading to both significant weight reduction and very low machining dimensions while retaining high stability. Common material developments together with steel works are an important element for component strength and the cost effectiveness of our products. Before we begin with the creation of tooling, we simulate and optimise the forming process of the later component using the latest FEM software.

CLOSED DIE FORGING

Precise drop forging forms the basis at STP for the manufacture of raw parts. Machinery from semi-automated hammer lines up to fully-automated walking beam lines support this. The process is constantly enhanced in order to optimise the component characteristics, quality and costs. Burr-free forging has already been implemented for many components and the forging process is being consistently further automated up to inline heat treatment.

HEAT TREATMENT

The +P process is being increasingly used in addition to standard processes such as case hardening, tempering, normalising and induction hardening. This uses a controlled cooling immediately after the deformation process from the forming heat (inline process). This extremely economical production combination is particularly suited to micro-alloyed AFP steels and bainitic steels which have been explicitly developed for this process.

TURNING AND MILLING

Our two precision components plants have 130 modern CNC machines with which we carry out all product-specific turning and milling work. The customised in-house automation enables us to optimise the production machinery with its complex processes in such a way that a high level of quality and profitability is achieved.

DEEP-HOLE DRILLING

Our seven deep-hole drilling units enable us to produce holes with a diameter range of 2.5 mm to 30 mm and a drilling depth of up to 700 mm. As a result, very high customer requirements for position and diameter tolerance and surface finish are able to be achieved.

GEAR CUTTING

We make use of various production processes in order to be able to meet the different kinds of spline requirements. We concentrate on making use of the most economical process while meeting all quality requirements. Using the “slotting” process we produce 700,000 shafts annually on our gear shaping machines with a maximum deviation in roundness of 0.015 mm. Using the “rolling” process we produce 2 million components annually with involute splines. For this we use five old rolling mills which achieve a deviation in roundness of less than 0.03 mm even for hollow shafts.

BROACHING

Using the “broaching” process we produce 1.5 million components annually with high-precision ball races. The high demands for a maximum straightness of 0.015 mm combined with a maximum parallelism of 0.02 mm are easily achieved within this process.

ASSEMBLING

In addition to the machining of individual components, we carry out the assembly of component groups in collaboration with various partners.

TESTING AND MEASURING

  • Latest 3D coordinate measuring machines
  • Contourographs
  • 3D laser scanners
  • Optical testing equipment
  • Surface measuring devices
  • Gear tooth measuring machines
  • Individual component-specific CNC test facilities
  • Test laboratory for material investigations