Completion of successful project
After over 3,500 hours, SCHAAF has completed its work on the world-wide largest drop forging press in underfloor design successfully. The 60,000-ton press is the largest private investment in metalworking for air- and space travel.
In august of 2015, SCHAAF received the approval for the engineering and supply of over 440 hydraulic (hydraulic-nuts, bolt-tensioning devices) and mechanical Bolt Tensioning devices (MSN) in the dimensions of M30 up to S1000 for one of the world’s largest drop forging presses in underfloor design. Included in the scope of delivery were over 140 customer specific ExpaTen-Bolts from Ø180 to Ø400 and up to 8,500 mm overall length, as well as special assembly equipment and pumps. Said components have been delivered throughout the last year.
The continuation of the assembly of the world’s largest drop forging press in underfloor design has been completed with the lowering of the 2,500-ton 7-segmented middle piece. This was achieved by tightly fitting the segments of the foundation via approximately 80 SCHAAF connection elements.
Section three and completion
Following the previous efforts, the crosshead was fully mounted: as in section one, the 300-ton heavy casting components were initially positioned to ‹ 1mm with ExpaTen and assembled tightly in a friction-type connection by using 8,5 m long ExpaTen bolts with Ø400 mm and cross anchors M490 / M400 and M355.
Finally, the last 1,500 ton heavy section can be lifted onto the pre-installed components. In order to give the press it’s full functionality, the last 4 main tier-rods have to be tensioned: with a length of 26m and a thread size of S1000x32 and a weight of 115 tons per piece, an unseen pretensioning force of over 150,000 kN had to be produced. This force equals the weight of approximately 25 Airbus A380 or 400 fully loaded semi-trailers per bolt.