ulus metal
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1 Ulus Metal 9-Apr-14
Transcript of ulus metal
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Ulus Metal
9-Apr-14
History :
• 1970 Production of stamped metal parts
for automotive industry
• 2007 Moved to a new plant in Gebze Industrial
zone on a 8000 m2 closed area.
• 2009 First non-automotive business started
• Total Number of employees : 125
• Number of shifts : 1 shift
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Worldwide Customer Portfolio
KYB Suspension Europe S.A.
Spain
TENNECO AUTOMOTIVE
Spain, Belgium, Germany,
Czech, Poland, USA
THYSSENKRUPP BILSTEIN
Germany, Romania, USA
ZF SACHS
Turkey, Germany, Slovakia,
Spain
MAYSAN MANDO
Turkey
ISUZU
Turkey
MAGNETI MARELLI
Poland
WABCO
Germany, Poland, USA,
Brasil, China, India
EMERSON Climate
Technologies
Northern Ireland, Czech
Republic, USA, Belgium,
China
KNORR BREMSE –
Hasse&Wrede Germany
AL-KO
Spain
KONI
Holland, Czech
RECORD France
GABRIEL Europe
France
BWI (DELPHI)
Poland
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Caps Bracket Assemblies
Spring Seats
Stabbar Brackets
Rolled Rings
Truck and LCV Chassis brackets
Shock Absorber Parts
Eyering
Assemblies Washers
Holders
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Overview Product Families
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Cooling Compressor Components Brake System Components
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Overview Product Families
Machined Parts
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Main OEM automotive projects 1/4
•ZF Sachs – Slovakia
• Fiat 330 Idea & Lancia &
• Grande Punto
Alfa 955 (Mito)
Y413 – XC60
•ZF Sachs - Germany
W212
MFA EVO
• Magneti Marelli
Fiat Fiorino 330
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Main OEM automotive projects 2/4
• ZF Sachs - Turkey
Fiat Doblo & New Doblo 263 & Fiat Palio & Fiat Albea
Renault L38 / Fluence
Ford Transit V184/V347 Ford Connect V227
New Transit V36X
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Main OEM automotive projects 3/4
• Maysan Mando - Turkey
Hyundai MC Renault Clio
Hyundai IA Symbol
• Tenneco (Monroe) – Germany & Belgium
BR172 SLK
Renault Clio 4 (X98)
Renault Trafic (X82)
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Main OEM Automotive projects 4/4
•ThyssenKrupp Bilstein - Romania & Germany
X90 911
NPR Trucks and NKR Light Duty Trucks Buses
Supplier for chassis parts.
• ISUZU - Turkey
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• Experienced Project Management
Team
• In house stamping die design and
manufacturing
• Production flexibility for AM and OEM
Projects
• Fast Prototype sampling
Ulus Metal
Project Management
•Reverse engineering for AM projects
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Toolshop
CAD systems :
Siemens NX, Mastercam,
EzCam
Capabilities :
Wire EDM
CNC vertical machining
CNC turning
Surface grinding
Conventional turning and
milling machines
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Transfer lines (600t-250t)
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Production Shopfloor
• Mainly for high volume
projects
• Transfer presses with 3D
transfer arms (X-Y-Z axis)
• 600 Tons
• 600 Tons
• 400 Tons
• 350 Tons
• 250 Tons
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•Transfer tool design and manufacture
Movie: Spring Seat Movie: Outer Bracket
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Production Shopfloor – Transfer Press
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Progressive lines
• Progressive tools for higher
volume parts
• Tool capability of on one shot
1 – 2 or 4 parts production
• 100 Tons
• 250 Tons
• 300 Tons
• 350 Tons
• 400 Tons
• 500 Tons
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Production Shopfloor
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•Progressive tool design and
manufacture
Movie: Inner Bracket
Steel band view of stabiliser bracket
Progressive tool for stabiliser bracket
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Production Shopfloor –Progressive Press
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Production Shopfloor
Hydraulic Press - Deep Drawing
• Hydraulic presses with hydraulic hole punching machines
• 600 Tons
• 250 Tons x 2
• 330 Tons
Movie : Production of deep drawn shell (2nd Operation)
Depth : 500 mm
Diameter : 275 mm
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Manual tandem stamping (400t-30t)
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Production Shopfloor
• Wide range of presses for less volume productions
• 40 presses from 30 Tons up to 400 Tons 9-Apr-14
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Production Shopfloor - CNC Machining
Movie : Production of muffler plate assembly
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Production Shopfloor
Shock Absorber Body Welding Line • Machines for producing Shock Absorber Body Assembly (Automated Welding Line, welding fixtures, press-fitting presses, leakage test units, punching presses, control fixtures)
9-Apr-14 Movie: Robot Welding of Bracket Assy
•Mag Welding Line
•100% parameter controlled Cloos
Welding Machines
•500A welding power source
•Servo controlled rotating movement
torch
•MAG welding on upper mount
assemblies
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•Spot Welding Line
•Projection welding – inner&outer
knuckle brackets, hose holders,
ABS cable holders
•Welding tools manufactured in-
house
•Welding power 300-400-600 kVA
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Production - Welding
Poka Yoke System for Renault Bracket Assy 9-Apr-14
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Auxiliary Operations
IN-HOUSE :
• Deburring
• Thread cutting
• Riveting
• Chamfering
OUTSOURCED :
• Surface treatment (Zn-Fe coating, Zn-Ni coating, KTL painting)
• Heat Treatment
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Raw Materials Used
MATERIAL TYPES
• Hot & Cold Rolled Steel
(DD11, DD12, DD13, S315MC, S355MC, S420MC, DC01, DC03, DC04)
• Profile material for rolled rings
• Stainless Steel
AISI 304 (1.4301)
MATERIAL THICKNESSES
From 0,5 mm up to 6 mm
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Ulus Metal
Measurement Capabilities
Laboratory capabilities • CMM DEA with PCDMIS-CAD ++ software with rotating and scaning probe
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• Shadow projector device • Pull-out test device (5t capacity) • Flatness measurement device • Welding strength test and penetration test devices
CMM Table Size : 1200x1500x1000
CMM Table Size : 2700x1000x6660
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Quality system certifications
Certified by SGS for • ISO TS 16949 ISO 9001: 2008 ISO 14001 OHSAS 18001
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New Investments
New Investments
• 800 tons Mechanical Transfer Press (Delivery in August)
• CNC Milling Machine
• Spot Welding Machine (750 kVa)
• Coil Feeders
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Contact information:
Company Name : Ulus Metal Sanayi ve Ticaret Limited Şirketi
Address : Gebze Organize Sanayi Bölgesi 1000. Sokak No. 1039 Gebze-Kocaeli/ Turkey
Telephone no. : +90 262 677 10 21 – 5 lines
Fax no. : +90 262 677 10 26
Email : [email protected]
Web site : www.ulusmetal.com.tr
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Thank you for your attention…
ULUS METAL
9-Apr-14
