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Welcome t o

Welcome t o. FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. FÉMALK plc Aluminium HPDC Foundry Öntöde u.10 H-1211 Budapest femalk@femalk.hu www.femalk.com. Location of the company. FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry Öntöde u. 10, H-1211 Budapest. Budapest, Hungary. 4.

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Welcome t o

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  1. Welcome to

  2. FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. FÉMALK plc Aluminium HPDC Foundry Öntöde u.10 H-1211 Budapest femalk@femalk.hu www.femalk.com

  3. Location of the company

  4. FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry Öntöde u. 10, H-1211 Budapest Budapest, Hungary 4

  5. FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry Öntöde u. 10, H-1211 Budapest 5

  6. FÉMÖNTÉSZETI ALKATRÉSZGYÁRTÓ ZRT. Aluminium HPDC Foundry Öntöde u. 10, H-1211 Budapest 4000 m2 9000 m2

  7. Important data and organization of the company

  8. Important data • Aluminium high-pressure die casting foundry • founded 1989 • family owned • 25,2Million € turnover in 2010 • 38 Million € turnover in 2011 • 46 Million € turnover in 2012 • Of which 100% automotive • 500 employees • 3 shifts on 5 days • 13,000 sqm area

  9. participation in designing of parts testing activates: dynamic and static testing designing of dies and machining tools building of dies and machining tools casting machining assembly Capability

  10. Main process (Pre-) Development Tool construction (Series- and Prototype tool) Validation testing Production: -Casting -Machining -Surface treatment -Assembly CAD Systems: Catia V5 R16-19 Pro/E Wildfire 3-4 FEM Systems: Ansys v12 Catia GPS Filling simulation: NovaFlow&Solid Quality planning, Quality control Quality monitoring 10

  11. Development and tool production

  12. Parts development Software: Pro/Engineer Wildfire 2.0 and 3.0 Catia V5 Possible Access to UGS/NX 12

  13. Direct development for the BMW 1 and 3 series • Transmissions bracket and Transmissions cross member • Project start end of 2009 • Part development • FEA calculations • Sand casting prototype’s • Mold construction • SOP 2011 July 13

  14. Direct OEM - New projects in 2012 Gearboxmounts Fastener Gearboxmount Engine mounts …and further 4 Development contracts for totaly 16 parts

  15. BMW i8 - Engine mount , Gearbox cross member

  16. FEA Simulation ANSYS v12 Linear and bilinear material properties Catia GPS Linear material properties

  17. Cooperation with Universities Budapest University of Technology • University of Miskolc • Aalen University

  18. Mould filling and solidification simulation • Software: • Nova Flow& Solid • Form fill-, solidification- and cycle simulation. • Temperature • Velocity • Solidification

  19. Mould design Software Pro/Engineer Pro/Engineer Wild Fire Version2 Mold design NC Machining

  20. Tool shop Machining Centre: Deckel-Maho 70V Excel MC-5V Dugard Eagle 850 Finetech SMV-1100 Lywentech Mythron HSM85A Lywentech Zeigler LZ-720 Spark erosion machine: Sodik AQ 55 Starthole drilling machine: Sodik K1C Wire spark erosion machine: Sodik AQ 35

  21. Production

  22. EN AC 44300EN AC-AlSi12(Fe) 230 EN AC 46000 EN AC-AlSi9Cu3(Fe) 226 EN AC 47100 EN AC-AlSi12Cu1(Fe) 231 Silafont 36 AlSi9MgMn Nevertheless we accomplish kindly special requests of our customers, too. Types of Aluminium alloys

  23. Smelting-shop Smelting furnace: Morgan Crucible furnace 500 kg 1 pcs. Striko Shaft furnace 2000/1000 2000 kg 1 pcs. Hormesa reverberatory furnace SH3.UB-G 3000 kg 1 pcs Hormesa reverberatory furnace SH3.0F-G 3000 kg 1pcs. Striko Westofen 4000/2000 2000kg 1 pcs. Smelting and Holding furnaces: Shaft smelt and holding furnace: 250 kg 5 pcs. Liquid metal treatment: Filter furnace 1 pcs. slag-, gas-, salt-, nitrogen treatment

  24. The foundry Casting cell: 23 pcs. Manual machine: 1 pcs. Locking force: 250 - 960 tons

  25. Horizontal HPDC machines

  26. Horizontal HPDC machines

  27. 960 ton Horizontal HPDCFrech casting cell

  28. 700t DGM casting cell 28

  29. Permanent temperature control of the melting furnaces Temperature of the smelting furnace

  30. Permanent control of the casting parameters Maschine 17

  31. Permanentcontrol of the casting parameters Immediate error message if parameters are incorrect

  32. CNC machining-shop ENSHU JE60 CNC machine 1 pcs Heckler &Koch BA20 CNC machine 2 pcs Mori Seiki CNC1 pcs Mori Seiki NH400 CNC machine1 pc Mori Seiki SL 1000 CNC lathe 1 pcs Doosan automatic CNC lathe 1 pcs Alzmetall CNC drilling- and crew machine 1 pcs Steinel BS500 multiple-spindle drilling machine 1 pcs

  33. Surface treatment Blasting process Overhead rail shot blasting machine (Schlick) Inline shot blasting tunnel (Trowal) Moulder belt shot blasting machine (Tauss) Deburring process Trough vibrator (Trowal) Circular vibrator (Rösler)

  34. Assembly CRIMPING Developed by FÉMALK ! Specialty: cold forming by 1,5% elongation of the alloy!

  35. Quality assurance system

  36. History of our Quality management system 11.02.2000: ISO 9002/QS 9000 27.07.2001: VDA 6.1 30.11.2002: ISO TS 16949 31.05.2005: ISO 14001

  37. ISO/TS 16949:2002 und ISO 14001

  38. Bosch preferredsupplier award 2011 and 2012 38

  39. Sándor JózsefBusinessman of the year 2012 by Ernst&Young

  40. Quality control 3D coordinate measuring machines

  41. Leak tester equipment Quality control Spectrometer 41

  42. Quality control X-ray

  43. Quality control Microscope Universal testing machine

  44. Products 44

  45. Products for vibration control trucks

  46. Products for vibration control passenger cars

  47. Top Mount for VW Golf, Passat, Audi A3, Skoda Roomster

  48. Top mount for shock absorbers

  49. Products for headlights

  50. Parts for air condition compressors

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