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Aluminium sheet and profile forming
SHEET BENDING
- Press brake (up to. = 4 000 mm, thickness max. = 3-4 mm)
- Crank presses (punching, dimpling etc.)
- Hand bending machines (bent lenghts up to = 2 000 mm, thickness max. = 2 mm)
SHEET ROLL-BENDING
- Roll-Bending Machine HAEUSLER
- Cylinder length up to = 4 400 mm, minimum radius = 22 mm, thickness max. = 3 mm
PRESSING OF FLAT SHEET – METAL PARTS USING RUBBER CUSHION
- FRICTION PRESS (parts up to = 360 x 360 x 40 mm, height up to = 40 mm)
- FLUID CELL PRESS
- parts up to 1 000 x 2 800 x 200 mm
- working pressure 25 MPa
- height up to 200 mm depending on the complexity
FORMING USING STRETCH
- Stretch forming presses
- Single or double curved formed across the block
- Height depends on stability of the block
| DIMENSION |
width (mm) |
length (mm) |
thickness (mm) |
max. cross section (mm²) |
| Longitudinal forming |
1 500 |
5 000 |
3 |
4 500 |
| Cross forming |
4 000 (4 500) |
2 000 (6 000) |
3 |
13 000 |
SECTION FORMING BY STRETCHING AND ROLLING ON BLOCKS
- up to = 4 000 mm
- max. cross section. = 250 mm2
PRODUCTION OF SECTIONS FROM SHEET-METAL STRIPS THROUGH DRAWING DIE
- length up to = 6 000 mm
- sheets up to = 2 thick
PRODUCTION OF ROTARY VESSELS BY SPINNING
- max. Al sheet thickness 2 mm, max. blank diameter hand extrusion 940 mm, machine extrusion 500 mm
Steel forming
Steel sheets forming on eccentric presses
- shearing, bending, drawing, push broaching, extrusion, forging and trimming
- work table dimension from 320 x 210 mm do 1 000 x 720 mm
- ram stroke from 8 do 125 mm
- bent lenght up to = 720 mm
Press brake forming
- bendign, straghtening and punching
- sheet thickness 1 to 12 mm
- work table dimensions 4 000 x 3 120 mm
- bent length up to 4 000 mm
Machining
TURNING OPERATION
- standard centre lathes up to 250mm in diameter and 1 250 mm in length
- automatic lathes up to 20 mm bar diameter
DRILLING AND BORING
- drilling machines (max. diameter 50mm, max distance between spindle and work table 1 345 mm)
- horizontal boring machines (work table 1 000 x 1 200 mm, height = 0 – 900 mm)
- coordinate boring machines (work table 1 000 x 1 600 mm)
GRIDING
- standard grinding machines
(centre grinding machines – external diameter up to 280 mm)
(centreless grinding machines ¤ 3 – 63 mm) )
(hole grinding machines ¤ max. 250 mm, ¤ min. 10 mm, length max. 250 mm)
- plane griding machines (part max.300 x 1 500 mm)
- cog grinding machine (module 1,5 až 6, ¤ from 30 to 315 mm, wheel width up to 100 mm)
- tool grinding machine (external ¤ up to 280 mm, centers distance 500 mm)
MILLING
- standard milling machines (parts up to 425 x 2 000 x 500 mm)
- gear milling machine
(module up to 7, wheel diameter up to 800 mm, teeth straight, helical, worm or chain)
- pantographic milling machine (220 x 440 mm. Reduction 1:10)
- single purpose milling machine for globoid and duplex globoid cogs and worms
- CNC milling machines:
| Name |
CONTROL SYSTEM |
|
BLOCK DIMENSIONS (mm) |
MOVES IN AXES x,y,z (mm) |
| V3 1600 B |
Heidenhaim 410 |
|
8 300 x 1 600 x 600 |
6 300 x1 600 x 500 |
| MRP-2 |
UNIMERIC 723 - 3D spindle |
|
12 000 x 1 590 x 700 |
10 000 x 1 600 x 600 |
| V 800 AN |
Heidenhaim 530 |
|
2 800 x 800 x 700 |
2 440 x 800 x 580 |
| MF 800 AN |
UNIMERIC 700 CNC - 3D |
|
2 600 x 850 x 700 |
2 440 x 800 x 580 |
| FUWx 315/6 |
CNC- H 646 - 2,5D |
|
710 x 400 x 354 |
500 x 400 x 330 |
| VF 1 TC |
UNIMERIC 200 CNC - 3D |
|
900 x 500 x 550 |
800 x 500 x 400 |
| FS 100 S/A3 |
Heidenhaim 426 - 5 axis |
|
3 000 x 1 000 x 900 |
4 000 x 1 000 x 900 |
ROUTING
- TRUMATIC NC milling machines
- bundle of sheets up to 12 mm thick, (3 000) 2 500 x 1 200mm
- Milling tool min. 6 mm diameter
Raw material cutting
- CORTINA S 2600 – NC oxygen cutting machine for steel sheets of 5 to 125 mm thick, working width 2 600 mm, cutting speed max. 7 m/min., cutting slot 1,6 – 4,6 mm
- circle saws (up to 40 mm in diameter)
- band saws (up to 250 mm id diameter, or 265 x 150 mm)
- table shears (width up to 2 300 mm, thickness up to 6,3 mm)
- curved shears, circular shears and vibration shears (width up to 1 000 mm, thickness 1,5 mm to 2,5 mm) >
- abrasive cutting machines
Slotting
- with a slotting machine (up to 270 mm in height)
- cog wheel machine (module 0,7 – 3, wheel diameter up to 315 mm)
Welding
Steel ARC welding
- carbon steel, alloy steel, cast iron and cast steel, by coated (basic or special coating) electrodes, material thickness min. 1 mm
- grooving by carbon electrodes, straightening
Steel mag welding
- carbon or alloys steels, thicknesses up to 8 mm
- for maintenance purposes - surfacing
Steel spot welding
- carbon or alloy steels, thicknesses from (0,5 + 0,5) to (3 + 3) mm
- max. thickness ratio 3:1
Steel TIG welding
- carbon or alloy steels and stainless steel
- copper, thickness from 0,5 to 10 mm
Steel oxy-acetylene welding
- carbon, alloy or stainless steels welding and brazing, thicknesses from 0,5 to 3 mm
Aluminium and Al-Alloy TIG welding
- for weldable materials, thicknesses from 0,8 to 10 mm
Aluminium and Al-Alloy oxy-acetylene welding
- for welding and brazing thicknesses from 0,6 to 5 mm
- washing in baths 2 800 x 680 x 1 230 mm
Aluminium and Al-Alloy spot welding
- for aircraft parts from (0,6 mm + 0,6 mm) to (2,0 + 2,0 mm), max. thickness ratio 3:1
- tests are necessary for thicker materials
Riveting
Manual riveting
- manual riveting for rivets up to 5 mm in diameter (Al-Alloy)
Machine riveting
- machine riveting on hydraulic and pneumatic presses for parts up to 1 500 x 6 000 mm
Radial riveting
- BRACKER radial riveter
- Al-Alloys rivets up to ¤ 5 mm (solid rivets) or ¤ 10 mm (tubular rivets)
One-sided riveting
- manual
- pneumatic, rivets up to ¤ 5
- Special fasteners pneumatic installation (Lockbolt GP a LGP ¤ 4 mm a ¤ 5 mm)
Surface treatment of aluminium
Computer-controlled automated line with recording and archiving data for processes:
Yellow chromating Alumigold B
- This coating provides corrosion resistance of parts combined with excellent adhesion. Thus treated surface is suitable for coating systems or application of powder coating.
- Usable internal dimensions of the bath: length 5500 x width 1900 x depth 600 mm.
Colorless chromating Alodine 1500
- The surface treatment provides corrosion protection of aluminum and is an excellent binder for transparent organic surfaces. It is used when the characteristic appearance of aluminum is needed.
- Usable internal dimensions of the tank: length 1800 x depth 800 x width 700 mm
Environmental testing of corrosion resistance
Hardening shop
Newly refurbished hardening shop, equipped with computer for monitoring, recording and archiving of data:
Heat treatment of aluminum
- salt bath for heating and cooling (solution annealing) of sheet metal parts such as aircraft structures
- processed materials Z424203, Z424253, AA 2024, ALCLAD 2024, DIN 3.1354, 3.1364
- max. size of parts: 5800 x 2000x 500 mm
Heat treatment of steel
- annealling, normalizing, hardening, cementation of the surface
- carbon steel,alloyed up to class.16 (according to ČSN)
- max. size of parts: 1200x600x450mm
Painting
- Painting with use of polyurethane, epoxy, acrylic, nitrocelulose and synthetic coatings.
- Painting Boxes 6 x 4 m, 20 x 7m. Painting Hall 60 x 32 meters.
- Experience with painting interior parts for aircraf, buses, train units, etc.
Other technologies
- XOTH - 32 A bending machine, from ¤ 10 do ¤ 32 mm pipe diameter for Al alloys and steel (yield strength 280 MPa). Constant bent radius from 25 to 200 mm, up to 110°C angle, raw tube length up to 3 500 mm.
- hand bending from 6 mm dia; Al alloys and steel tubes filled with sand or press fluid
- tube expanding machine for Al alloys and steel tubes with cap nuts from 6 to 45 mm diameter and length up to 3 500 mm
- tube from 12 to 65 mm dia. Reducing, with interstage annealing on larger sizes, Al alloys
- Grooving tube ends for Al alloy tubes from 8 to 45 mm
- control rods production (Al alloys)
Hose armouring
- low pressure from 4 to 32 mm nominal inside diameter
- high pressure from 4 to 16 mm nominal inside diameter
- pressed – inside diameter 8 mm
Rope end pressing
- eccentric presses (63 t press, ropes from 2 to 6,3 mm diameter; 100 t press, ropes from 8 to 10 mm in diameter)
- pre-stretching up to 40 kN, length 21 m
- swaging per 239 AT
- swaging of NICOPRES sleeves
Rod and pipe reduction
- for rod reduction from 20 mm in dia down by 3 mm – 1 mm steps
- for tube reduction from 30 mm in dia, wall thickness up to 6 mm
- shaped mandrels can be used for swaging of grooved, square, hexagonal etc. cavities
Plastics and composite processing
- vacuum forming of up to 910 x 1 919 x 400 mm for interior aircraft parts, max. thickness 5 mm
- forming and curing of glass prepreg structures
- positive shape forming of plexi-glass up to 800 x 1 200 mm
- negative shape forming in plexi-glass up to 1 500 x 1 800 mm
- forming shapex in a split mould of up to 600 x 1 000 mm
Production of cable bundles
- with plugs or sockets, soldered or pressed
- cable making – thermal printing of TMS marking tubes
Upholstery works
- light sewing machines, curtain sewing, insulation, and packing fabric covers manufacturing
- gluing with CHEMOPREN or VUKOPLAST D420
- materials: fabric, leather, man-made leather, waterproof fabric, fabric covering, canvas, rubber, rubberized hair, polystyrene, polyurethane roam, carpets, foam rubber etc.
- interior upholstery manufacturing
Production of special Tools and Fixtures
Turning fixtures
- milling machines
- lathes
- boring machines
- grinding machines
- slotting machines
- pull broaching machines
- drilling templates
- special purpose shop equipment
- tools (shaped knives, special bits and reamers)
- milling cutters - shaped
- CNC
- gauges for spindles, holes, and special single purpose measuring equipment
- boring fixtures and jigs
Forming, bonding and welding fixtures
- press cutters
- pressure moulds
- ruber moulds
- blocks
- injection moulds for plastics
- bonding jigs
- forming jigs for plastics
- laminating tooling
- bending jigs and tube tooling
- welding fixtures
Fixtures for assemblies and installations
- assembly fixtures of up to 30 m in length (4 x 4 m in cross section)
- riveting equipment
- ream and bore units
- final assembly platforms, jigs, tools and stands, transport equipment
- hydraulic and air conditioning test equipment
- measuring equipment
- positioning equipment
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