Quintus FLEXFORM Presentation

I I05/01/2023Confidential 1

FLEXFORMFluid Cell Press Technology


• Quintus Technologies, brief background • Flexform technology overview• Examples

– Prototyping and Low volume production– Business cases

• Workshop tour• Summary and conclusion


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2015200520001990198519641953 1970 1980

Sale of Company to

Flow International

FLEXFORM

introduction to the

automotive industry

Introduction of food

processing presses

Introduction of

FLEXFORM presses

Introduction of isostatic

presses

Company produces the

world’s first synthetic

diamond

1940-

1950

Company formation

under ASEA (later ABB)

ownership

Introduction of the

Avure brand

http://upload.wikimedia.org/wikipedia/commons/8/8c/Asealogo.gif



Office

Workshop



Advanced Material Densification

Sheet Metal Forming

50 Years of High Pressure Innovation



• Prototyping and Low volume production• Business cases



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Sheet metal is formed over one shape defining tool half by a flexible rubber diaphragm, backed up by high hydraulic pressure:

The blank is placed on the rigid tool half. The press table is moved into the press where the diaphragm is located.Oil is pumped into the press above the diaphragm which is forced by the oil pressure to wrap the blank around the tool.After decompression, the press table is moved out.

Videos of this process can be found on:www.youtube.com Flexform press

Flexform – The Forming Principle


Tray

Tool

Pressure Fluid Inlet

Pressure Fluid Reservoir

Blank Material

Diaphragm

Formed Part

Flexform – The Principle of Flexform


Prototyping & Low Volume Production, Daimler

2.0x4.0-1400150,000 ton Press force

150,000 ton Press-force World-record

Prototyping. Ford1.8x3.6-1000

94,000 ton Press force

Aerospace ProductionEmbraer, BrazilPress 0.8-800

4,000 ton Press-force

Flexform – Small to Large Presses

Flexform – Sheet Metal Forming Division






“Scuffplates” XC90 R-DESIGNStainless steel, brushed surface t=0.8mm, 1.700x150mm, depth ~100mmSerial Production Life Cycle > 7 years, 1.500-8.000 per year

Volvo

Exhaust treatment systems~40 different prototype parts for exhaust treatment systems to heavy diesel Engines (Euro 6)”Almost stainless steel”; t=1.0 – 3.0mm (Size: Max 1200x1200x150mm)Project time 1 – 2 years, 2-3 loops, ~30 sets/loop

SWENOX, now Eberspächer

Examples: Automotive – Low Volume Serial Production & Prototyping


Pre-painted = OK Wind shield

Examples: Automotive – Low Volume Serial Production & Prototyping


Fork protection

PanelsTank Housings

Trim ring

Fender

Seat bottom

Muffler

Fender

Chain guard

Plate holder

Panels Air filter box/ air intake

http://www.google.se/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCMzYs9u7h8YCFaku2wodvvUANA&url=http://www.latimes.com/business/autos/la-fi-hy-ducati-2015-scrambler-20140924-story.html&ei=fmd5VcyhCqnd7Aa-64OgAw&bvm=bv.95277229,d.bGg&psig=AFQjCNEutkYCRctUlzBtDqbV5EnzoW1Pzg&ust=1434106109223453


• use Flexform for all external prototypes and for pre-serie production

• Pre-draw by conventional pressing

• Calibration and flanging in low cost Flexform dies


Engine hood & door panelCarbon steel, DC04; t=1.5-2.0mmSeries production, 20-300 machines/yearThe yellow has a hood where different articles are Laser Cut from the same pressed geometry

Forestry machinery

Construction equipment –Low Volume Serial Production


Forklift engine hoodCarbon steel, DC04; t=2.0mm (1500x900x250mm)Series production, 50-300 machines/year

Forklift coversCarbon Steel, DC 04; t=3.0mm, 700x600mm, depth 260mmCycle was ~8 years, 3.000-8.000 sets/year

BT Products (Toyota) Forklifts (Kalmar)



Top Covers and Side CoversCarbon Steel, DC 04; t=1.5-.0mmLife Cycle over > 10 years5-50 machines/year

Cooler, front & full body-casing Two models in production, 3rd one in the pipe-lineCarbon Steel, DC 04; t=2.0mm, Broad variety of sizesLife Cycle > 10 years, 5-50 machines & type/year

Demolition Equipment




Guard irons ”Snow Plow”,Carbon (355MCE); t=6.0mmWagon gables, Stainless (yield strength ~320); t=0.8mm)Series production, ~200 trains in total

NOTE: Upgrading of guard irons for X2000 made the customer focus on Flexform

BOMBARDIER

TransportationLow Volume Serial Production



Building covers + DesignLow Volume Production


Hat ShelfBus Door

Inner Roof PanelTruck Cab Rear Panel

Inner Door

Commercial vehicles –Low Volume Serial Production


Low volume Prototyping +Concept Cars




Front, Engine hoodCarbon steel, DC04 T; t=1.5-3.0mm100-300 per yearDesign styling! Flexform provide the flexibility

Bumper in 3parts (one middle, two corners)Carbon Steel, DC04; t=2.0mm, 600 (1200)x300mm, depth 250 (120)mm Life Cycle ~10 years, 50-300 per year




Truck RoofLow roof for car transport trucks (made in two halves)Carbon Steel; t=1.25mm, 1200x1400mm, depth: 180mmProduct Life Cycle > 10 years,50-300 Trucks/year

Truck Panels and Structure parts

Different prototype parts, mainly to cockpits(A few of these samples pointed at by arrows)Carbon steel, DC 04; t=1.0-3.0mmProject time 0,5-1,5 years, 1-3 loops







Cost comparison, Hood Inner (Aluminium)

Conventional FlexformTool cost: 239,000 € 22,800 €

(pre-draw & re-strike) (one tool only)Part cost: 348 €/each 478 €/each

Total cost 50 pcs: 256,000 € 47,000 €

Total saving: 256,000 – 47,000 = 209,000 €

Business case: Automotive – Low Volume Serial Production & Prototyping


Two sub-suppliers withtwo different techniques:

Conventional pressing: 600 kEUR Flexform: 160 kEURSaving: 600 - 160 = 440 kEUR



30

13 part numbers for production

Conventional pressing:3 700 k€ investment7.3 k€/batch

Flexform:220 k€ investment98 k€/batch

Break even: 39,000 batches



0 EUR

500 000 EUR

1 000 000 EUR

1 500 000 EUR

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0 5000 10000 15000 20000 25000 30000 35000 40000

Parts

Conventional

Flexform



1 2 3 4 50

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10000

15000

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Series1Series2

1 2 3 4 50

100000

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Parts (Life time)

1 2 3 4 50

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20000400006000080000

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Series1Series2

Tool: 40x16x2,8dm

Tool: 16x10x2,8dm Tool: 10x8x1,4 dm

~11 000 parts

~5 500 parts

~3 400 parts

~850 parts

Sum cost(Tool+Parts

)

Sum cost(Tool+Parts)

Parts (Life time)

Parts (Life time)

Parts (Life time)

Tool: 20x16x2,8dm

Sum cost(Tool+Part

s)

Sum cost(Tool+Part

s)

For guidance only!

Break Even – From 1,000 to 40,000 parts(Laser Cutting excluded )


Cost Reduction - Increased Profit lower costs due to 50-90% tool cost reduction lower costs due to eliminating or reduction of process steps (intermediate heattreatments, hand correction) lower costs by late tool changes lower costs since several different parts can be produced within one tool lower costs, trimming of parts may be included in the tool Reduced lead time - >50% reduced lead time – serve your customer quicker Increased flexibility

different parts in sizes, thickness and length can be produced witihin one cycle undercuts are possible Robust System - 100% Swedish Engineered, many machines running since over 50 years High Quality – high forming capability, scratch free parts, tight tolerances, shape edges High Competence - over 50 years in the market Proven track record – Globallly over 1.700 installed machines Easy to operate

Increase your quality, lower your costs and increase your profit by choosing Flexform

Your Benefits


• Reduced Springback

• Reduction in part scraches

• One tool, different sheet thicknesses and different materials

• Materials from 0,1-10 mm can be formed

• Steel, Aluminum, Stainless steel, Ni alloys and Ti alloys

• Form undercuts without complicated tools

Benefits Flexform vs. “Conventional” forming


Randy KishBusiness Development ManagerMetal Forming

[email protected], Mobile: +1(614) 440-4360Office: +1(614) 255-6658

The Global Leader in High Pressure Technology