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BALINIT FORMERA 초고장력 강판 성형의 문제 해결

Chassis forming application

승객의 안정성을 향상시키는 동시에 배기가스 규제를 준수하기 위해, 미래의 자동차는 보다 견고하면서도 가벼워야 합니다. 따라서, 새로운 차량은 이전 모델보다 현대식 고강도 강재를 더 많이 사용해야 합니다.

이처럼 까다로운 강철 성형에 있어 높은 생산성을 보장하기 위해서는 특히, 탄성이 우수한 코팅 솔루션이 필요하며 그 대표적인 예가 BALINIT® FORMERA입니다.

  • 비교 코팅보다 최대 680% 높은 효율성
  • 탁원한 내마모성
  • 뛰어난 코팅 밀착력

Turbo-charging tube production

Although threaded plates are often invisible, they have an important role to play in vehicles. Forming specialist Kauth has used its in-depth expertise to perfect the production process: It combines clever techniques, including presses at up to 2,500 tons of pressure, punching and deep-drawing, with its unique tube technology – and BALINIT® FORMERA. This CrAlN-based coating from Oerlikon Balzers has transformed the service life of Kauth’s forming tools from a few hundred to over 60,000 manufactured parts.

Turbo-charging tube production

Unique tube technology
The German state of Baden-Württemberg has always produced impressive numbers of creative minds and inventors. One of them is Friedrich Kauth, who developed the unique tube technology with a major automotive manufacturer back in the 1970s – and it remains a unique selling point for the Kauth Group to this day. The company uses this technology to manufacture threaded plates, hinge systems, axle mountings, seats, engines, transmission systems and tank and exhaust system mountings that are used in vehicles around the world.

A tube is an extruded hole manufactured by gradual deep-drawing combined with punching a steel sheet using progressive dies. Unlike nuts welded onto sheet metal, the part is produced in one piece, with no weak points or associated risks of breakage or corrosion.

Delighted with the results: Johannes Kauth, COO Kauth Group (left), and Robert Karle from Oerlikon Balzers (right).

Designed to withstand 9 tons
Threaded plates can be welded onto various chassis components in order to fix other components and parts in place and to increase safety in areas subject to high forces. “For example, when installed in the rear wheel axle suspension, our parts can each withstand a load of more than 9 tons,” says Johannes Kauth, part of the management team at the family-owned company.

Drawn and upset
The high stability is achieved by strain hardening the drawn metal during the forming process. The steel strip material is first drawn in width, then in height, and then upset again to form the tube. For the threaded plates, this happens in a 1,000-ton press using a tool made of powder metallurgical high-speed steel (HSS) manufactured by Kauth.

Lubricating oil is useless
When a tool is subjected to such high forces, even extensive use of lubricating oil won’t protect it from damage. “After a few hundred strokes the wear becomes too extreme, so we only work with coated tools,” explains Tobias Wenzel, Head of Tool Maintenance. To this end, Kauth has worked alongside its coating partner Oerlikon Balzers for more than ten years.

"Coatings are the only way for us to increase tool service life to 60,000 manufactured parts. That pays off."

Johannes Kauth, COO Kauth Group

BALINIT® FORMERA comes out on top
In the production of threaded plates, one CrAlN-based coating clearly stood out in various tests: BALINIT® FORMERA. This special PVD (Physical Vapor Deposition) coating scores highly thanks to its virtually unrivaled wear behavior, a coating thickness of around 10 μm, and a special surface finish that reduces friction.

A coating that pays off
The transfer punch of the modular tool is coated with BALINIT® FORMERA to increase its service life to more than 60,000 manufactured parts. “We can quickly replace these wear parts, and the longevity of the coated tool ensures low machine downtime. That pays off,” explains Wenzel, and not just because around 7 million pieces a year are produced solely for this threaded plate project: Coatings mean higher process reliability across the entire business, of which the in-house toolmaking division is a crucial part.

“Our threaded plates and tube technology have become indispensable in German automotive construction,” says Kauth. The company is a technology leader in this industry, capable of manufacturing ultra-solid tubes, thickening material at critical points, and drawing sheet steel up to 80 millimeters. Very few companies can boast this expertise, which is also needed for electromobility: Battery technology tends to make vehicles heavier, which means that structural parts require increased stability and strength. And in this respect Kauth is leading the way with its future-proof solutions.

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Petra Ammann

Petra Ammann

Head of Communications Oerlikon Balzers
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