Precision for a moving world - Deutsche Messe AGdonar.messe.de/exhibitor/hannovermesse/2017/X800317/...Organisation SONA GROUP SONA HOLDING Automotive Components Services Support SONA

Precision for a moving world

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2 | SONA BLW

The vision of a leading precision for-ging group with a global footprint wasthe basis for the creation of SONA BLWGROUP in 2008. Through the merger,the Sona Group became a truly globalplayer and the SONA BLW GROUPmoved to one of the leading groups inthe precision forging business with pro-duction sites in three regions.

We are using the global partnership toalign our business activities to meetthe requirements of our customers.The three operating regions are SONABLW GROUP’s strength, in terms ofproduction as well as culturally. Thegroup combines the great heritage ofEuropean technology and market lead-ership with the dynamics of a qualityleader in the Indian automotive indus-try. We are prepared to respond to theincreasingly global market environ-ment. “Precision for a moving world” isnot only our motto, it is also a synonymfor our commitment to our customersunder continually changing conditions.

SONA BLW GROUP’s strategy is to con-tinue to be one of the leading precisionforge worldwide, to take an active partin our customers’ globalization strat-egies and to offer first class worldwidesupply. We are pleased to have theopportunity to guide you through theworld of precision forging on the follo-wing pages. Please read on to find outmore about the origins of our auto-mobile products!

Dr. Surinder KapurCompany founder and CEO of the SONA GROUP

Precision for a moving world


SONA BLW | 3

Selma, USA

Gurgaon,India

Pune,India

Munich,Germany

Duisburg,Germany

Remscheid,Germany


Organisation SONA GROUPSONA HOLDING

Automotive Components Services Support

SONA KOYO STEERING

SYSTEMS LTD.

SONA FUJIKIKO INDIA

LTD.

JTEKT SONAAUTOMOTIVEINDIA LTD.

Fuji Autotech Europe

AMERICANAXLE-SONAPVT. LTD.

ArjanStampingsPVT. LTD.

SONA SOMICLEMFORDER

COMPONENTS LTD.

SONAOKEGAWAPRECISION

FORGINGS LTD.

SONA BLWGMBH

Germany

SONA BLWInc.USA

MAHINDRASONA LTD.

SONA MOBILITYSERVICE(SIXT)

SONA E-DESIGN &Technology

SonaAutocomp

France

Koyo-SonaElectronics

Ltd.

SonaAutocomp

USA

4 | SONA BLW


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In six plants 2.000 employees manu-facture precision forged gears and axlecomponents and even parts for heavy-duty vehicles. The plants are locatedin Remscheid, Munich and Duisburg(Germany), in Selma (US) and also inGurgaon and Pune (India). Our strengthis the Group and our core competenceof precision forging according to cus-tomers requirements.

Our most important goal is to ensureour customers’ satisfaction by delive-ring high-quality, reliable products withinnovative features. Our continuous ef-forts are geared towards increasing pro-ductivity, quality, and reliability. Thisfact, coupled with ongoing innovationsand system integration activities, andthe strength of the SONA BLW GROUPenable us to offer to the costumers theideal solution for their projects.

The performance of our developmentand manufacturing engineers in thearea of precision forging sets usapart. As the inventor of the precisionforging technology we have followedthe process till the end. Our expertise isbased on the development of trans-mission and axle components, and thehigh quality of our tool and die manu-facture. The precision forging process

is gaining worldwide importance inmachinery, controls, and technology.Our components link the demands ofmodern high-performance constructionin component design and operationalsafety on the one hand with costeffectiveness and quality of productionon the other. We are also expandingthese core areas of expertise intomechanical processing, following thetrend of pre-finished, ready-to-assemblecomponents.

In all, we are investing an immenseamount of energy to link novel pro-duction processes with future develop-ments – such as our light differentialprogramme, which works to transferever-higher dynamic loads with ever-lighter construction techniques.

The heavy demand for precision auto-mobile components provides SONA BLWPRÄZISIONSSCHMIEDE – an automobilecomponent supplier with worldwide operations – an excellent opportunityfor further growth. In addition toimportant business with well-knowncustomers in Western Europe, weparticipate in the rapidly growingmobility markets of Central and EasternEurope and Asia. We can offer our globalthinking to customers local solutions.

Our Strength is the GroupSophisticated forgings for the heavy-duty vehicle industry supplement ourwide range of products. We use auto-mated forging equipment to manu-facture steering knuckles and precision-forged components for the commercialtruck industry. These products com-plete our profile in order to fulfil thedemands of the market.

The millions of axle and transmissioncomponents that we have already delivered to our costumers serve asevidence of our competency and com-petitiveness.


6 | SONA BLW

Development and EngineeringOur main goals consist of more thanjust the serial production of transmissioncomponents. Component design andoptimization with regard to functionand costs are also essential for fulfillingour customers' needs. The highly motiv-ated engineering team of SONA BLWPRÄZISIONSSCHMIEDE tackles con-tinually increasing demands and usesthis motivation to develop and imple-ment the optimum solutions for indi-vidual customers.

Differential bevel gear

CAD software solid model > FEM-readiness simulation > CAM tooth area for tool construction derived from solid model

We are constantly searching for new,more efficient techniques. These tech-niques have been implemented in thedesign and production of complex,high-strength forgings. Individual solu-tions and method development in com-ponent and process engineering arefurther elements in our ongoing missionfor higher efficiency.


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tool from

Precision Forgings


8 | SONA BLW

Development and EngineeringWe are continually reducing our devel-opment times and improving our simu-lation and calculation techniques. Ourexperienced engineers make this pos-sible with continuous preparation foreven shorter development times, in-creased system integration, new mater-ials, reduced weight at higher load re-quirements, and even more efficientproduction techniques.

Synchroniser ringsSpeed gears

Simulation of material flow to determine the theoretical

production process of a transmission gear

with dog teeth.

We keep the “moving targets” in oursights: including cost reduction, im-provements in quality, and weight re-duction.


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Bevel gear Helical gear

Precision Forgings


10 | SONA BLW

The independent operation “ZentraleWerkzeug- und Gesenkbau” suppliesall Präzisionsschmiede productiontransmissions and machining opera-tions. We moved into a newly erec-ted, high-tech manufacturing facility.Tools are planned, manufactured, andtested for all of the production tech-niques used in-house. These includeprecision, Hatebur, and crankshaftforging tools, as well as machiningdevices, tool and die holders, and thenecessary measurement equipment.The corporate-wide cooperation in thisarea creates synergies and competit-ive advantages.As a result of our ongoing work inresearch and development, we havebeen able to implement our ideasusing cutting-edge technology andtools such as CAD/CAM.

The latest machine tools are used tomanufacture highly complex toolsand equipment.

Tool and Die Construction

Tools and dies

HSC molding cutters Radial drills with tools on a CNC-turning machine


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Technologies

HSC molding cuttersCNC and conventional molding cuttersCNC turningWire-cut EDM, die sinking

NC-grinding / non-circular grindingStarthole erosionEngravingMeasurementJigmakingBracket and tool assemblyWelding

Quality control

Precision Forgings

Die sinking

Future Products

Tools for sheet metal formingEDM electrodesPrototype constructionPlastic mold constructionDie casting moldsJigmaking incl. constructionMeasuring equipmentTools for the forging industry


12 | SONA BLW

Daim

Flexible packaging according to customer demand

HSC-molding machining of electrodes and forming tools

SONA BLW PRÄZISIONSSCHMIEDEGMBH designs and manufactures trans-mission, axle, and engine componentsfor passenger cars, commercial vehicles,and rail systems.

Universal quality, from the tool to the finished part

Precision hot forging and functional surface calibration

Differential components for passengercars are an important part of thePräzisionsschmiede product portfolio.Präzisionsschmiede customers in thisarea include virtually all of the well-known automotive manufacturers.


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Daimler

The Precision Forging Process Chain

Cold forging

Warm forgingProcessing on fully automatic machining centers

Finish machining of precision forged parts

Heat treatment precisely adjusted tomatch the product and the productrequirements

We ensure that our factories have cut-ting-edge technology and equipment forthese demanding tasks. There are sep-arate departments for gear calculation,dimensioning, design, research, and pro-duct optimization.

Automotive World


14 | SONA BLW

FormingSONA BLW PRÄZISIONSSCHMIEDE hasstood for innovative, cutting-edge for-ming technology for more than 50years. A wide spectrum of presses ran-ging from 630 to 2,500 metric tons (incombination up to 5,000 tons) are usedto manufacture our components.

We are able to master all small andlarge series production with compo-nent weights ranging from 0.2 kg up to25 kg using various levels of automation.Warm (900 to 1280 °C), semi-warm,and cold forging processes are used forthis purpose.

Stub shaft Axle stub

Spline shaft Steering gear

We selectively combine these tech-niques to provide the highest level ofprecision and cost-effectiveness.


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Forging process

Speed gearCam lobes

Precision Forgings


16 | SONA BLW

We are one of today's leading providersof precision forged, finished differentialbevel gears for passenger cars andcommercial vehicles, and service virtually all of the well-known auto-motive manufacturers. This is due tomore than just our formidable expan-sion in capacity over the past few years.It is also due to advanced techniqueslike finish rolling, hard broaching andhard turning.

We have stayed ahead of market chal-lenges by mastering the entire preci-sion forming processing chain. State-of-the-art machining and our continuoussearch for new methods ensure thatwe stay at the cutting edge. A centralfocus of our work is to ensure that ourcustomers' processes function smoothly.

Mechanical Processing

MachiningCalibrating

With our innovative team we guaran-tee that the further development of ourproduction methods will allow us andour customers to continue to set mar-ket standards well into the future.


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All our plants are certified according toISO/TS 16949 and DIN EN ISO 14001.Continuous improvement is our motto.We work intensively to further increasethe quality of our processes and pro-ducts with Six Sigma programs.

Broaching of inner splines

Precision Forgings


18 | SONA BLW

The SONA GROUP entered the com-plete differential business on requestof our customers 18 years ago. Thiswas a logical step through our expertisein developing differential bevel gears.Today the SONA GROUP supplies 1 mil-lion differential modules per year. Oursuccess in the segment is the result ofa customer based organisational philo-sophy and investment. This as well asour technological competencies enablesus to constantly meet the exact stand-ards set by our customers.

As an automotive supplier we activelytake part in the development of futuretechnologies. For this purpose we havea dedicated testing rig for completedifferentials at the SONA BLW plant inMunich. Our test facilities enable us toguarantee product quality.

Differential AssemblyWithin the SONA BLW GROUP we areconstantly looking into new materialsand technologies as in case of our lightweight differentials. We currently workwith several customers on advanceddevelopment projects in this area.

Light-weight differential concept: Sheet metal


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Complete differential assembly

Light-weight differential concept: Aluminium

Precision Forgings


20 | SONA BLW

Kvernel

and

BPW

Faivel

ey

Mahle

MAN

DAFScania

Caterpillar

The Duisburg plant produces high-quality, highly sophisticated forgings ina weight range from 5 to 250 kg witha specific focus on high-strength applications. The forgings are manu-factured using five partly or completelyautomated forging press lines and acounter-blow hammer.

Our international clients include manywell-known utility vehicle manufac-turers, producers of large engine com-ponents, construction and agriculturalequipment companies, and customersin rail and traffic engineering.

Sophisticated Parts for Heavy-Duty Vehicles

Stub axle

Our world-class tool shop ensures thatwe can respond quickly and flexibly tothe wide variety of requests from ourcustomers. We have the ability to sup-ply our parts from small to mid-sizedproduction runs, as well as provideparts that are heat-treated, mechani-cally rough or fully machined, or ready-for-assembly.

We use state-of-the-art CAD/CAM techniques supported by computer-based Quality Control systems duringthe entire production process. As aresult, these techniques ensure thatwe continue to supply first-class forgedproducts to match our customer's exact specifications.

Spring brackets


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Mechanical ProcessingSteering knuckle

Tooth segments

Heavy-Duty Vehicle Components


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Development and Engineering

Die productionWheel brake disk for rail vehicles

Our sophisticated product portfolio isrecognized globally and includes com-plex fully-finished parts, with a particu-lar focus on the “Heavy-Duty VehicleIndustry.”

We increasingly develop components inclose cooperation with our customersand as a result of continued invest-ment and development, are able tointegrate functional elements into theforging design. Our latest design andmanufacturing techniques also allowus to offer component weight optim-

CAD model of a steering knuckle for trucks

for development of forging process

ization centred around carefully con-sidered material selection as well as thecapabilities of the forging process.

Ongoing process improvement is a wayof life for us. Once a new process ortechnique is fully developed and proven,it is incorporated into our productionactivities at the earliest opportunity inorder to maximize the benefits to ourcustomers.


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Hub shaftPiston upper sections

Steering knuckle

Heavy-Duty Vehicle Components


SONA BLW PRÄZISIONSSCHMIEDE GMBHPlant Munich

Frankfurter Ring 227D-80807 Munich, Germany

Phone: +49 (0) 89 32306-0Fax: +49 (0) 89 32306-159

SONA BLW PRÄZISIONSSCHMIEDE GMBHPlant Remscheid

Papenberger Straße 37D-42859 Remscheid, Germany

Phone: +49 (0) 2191 15-0Fax: +49 (0) 2191 15-1361

SONA BLW PRÄZISIONSSCHMIEDE GMBHPlant Duisburg

Friemersheimer Straße 40D-47249 Duisburg, Germany

Phone: +49 (0) 203 732-0Fax: +49 (0) 203 732-222

02.2

010

SONA BLW PRECISION FORGE INC.

500 Oak Tree DriveSelma, North Carolina 27576 - US

Phone: +1 919 965-5555Fax: +1 919 965-0123

SONA OKEGAWA PRECISION FORGINGS LTD.Plant I

Sona Enclave, 39 KM-DehliJaipur RoadGurgaon (Haryana) – 122001 / India

Phone: + 91 124 403 0192-95Fax: + 91 124 410 4639

SONA OKEGAWA PRECISION FORGINGS LTD.Plant II

T-46, MIDC Bhosari Industrial AreaPune-411 026 / India

Phone: + 91 20 30965619Fax: + 91 20 2027126843

E-Mail: [email protected]: www.sona-blw.com


Documents

Precision for a moving world - Deutsche Messe AGdonar.messe.de/exhibitor/hannovermesse/2017/X800317/...Organisation SONA GROUP SONA HOLDING Automotive Components Services Support SONA