Ecological and without transport requirements
The Forge has just introduced a unique method to wax semi-finished gearbox wheels
mong the top products that are first in line to get a clear shape in the Forge is the fourth-gear wheel in the DQ 200 gearbox. The part’s clamping surfaces require high accuracy, which is why production also involves special technological procedures. “Unlike other forgings, this part is specifically processed for synchronisation purposes”, explains Miroslav Kasík from the PKG/3 – Foundry and Forge Technology department. Thus, the entire forging process is completed by cold forming – calibration. “It requires a surface treatment, that is, the application of a sliding layer to ensure that the forming process runs smoothly with regard to the part’s geometry and the tool’s lifespan”, Kasík emphasises.
kilometres is the annual mileage between Mladá Boleslav and Kyjov that this novelty has now eliminated
tonnes of material consumed annually for semi-finished fourth-gear wheels for the DQ 200 gearbox
parts waxed per shift in the Forge
Previously, the sliding layer had been applied by phosphating and soaping the part at the supplier’s premises in Kyjov in South Moravia. In addition to demanding logistics, this also required a lot of water, energy and chemicals and produced waste that had to be disposed of. When the current supplier of die lubricants came up with a novelty to eliminate these problems, the choice was clear. It is a water-soluble wax that saves the environment much more than phosphating does. The part is soaked in wax and then dried; the whole process takes only four minutes. The wax bath is heated to only 60°C, and the part is then dried with warm air. The bath does not exceed a volume of 500 litres and has a low concentration and a long life of several months. The only waste remaining is polluted water, which is easy to dispose of as it contains no hazardous waste.
Integrating this device into the current manufacturing process was simple. A workplace consisting of three sections – a control roller, a waxing machine and a calibration press – was set up. “Thanks to this, we have reduced the manufacturing cost for one forging and contributed to a significantly positive benefit for the environment: a low consumption of energy, water and fuel and a reduction in emissions during transport by trucks”, concludes Kasík. Eva jarošová