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CHALLENGE
The automotive industry faces the significant challenge of reducing vehicle weight to lower emissions without compromising safety. Recent years have seen an evolution in manufacturing processes for chassis components and reinforcements, transitioning from traditional cold stamping to hot stamping and introducing new processes like tailor blanks with varying thicknesses.
To achieve weight reduction, steel manufacturers have developed new high-strength steel (HSS) and ultrahigh-strength steel (UHSS). However, these materials require increasing force proportional to their hardness, posing a challenge for stampers. Some OEMs have even proposed these steels as alternatives to Press Hardening technology in new platforms, further complicating production processes.
SOLUTION
Fagor Arrasate responded to these new market demands with large transfer presses as the ideal solution for producing structural and chassis reinforcement parts in HSS. These presses provide a much more productive alternative to hot stamping processes and can serve as a real substitute for mid-sized tandem lines.
The presses’ large size allows them to produce two parts per stroke, such as left and right components in symmetrical upper and lower body parts, significantly enhancing productivity. By leveraging advanced design and automation, Fagor Arrasate ensures their transfer presses can handle the high stresses associated with forming and cutting tough new materials.
Country USA
Solutions Transfer Presses
Sectors Automotive Aluminium
IMPLEMENTATION
Gestamp trusted Fagor Arrasate for a high-performance stamping line to be installed in the U.S. This transfer press, offering 32,000 kN of force and a bolster measuring 7500 x 2700 mm (24.61 x 8.86 ft), is capable of stamping up to four parts per stroke.
The entire stamping line is a 100% Fagor Arrasate solution, including the CNC7S transfer system that handles HSS parts up to 2,200 mm (86.6 in) wide. Advanced automation is exemplified by the CT transversal blank destacker, which operates at speeds of up to 40 spm and can handle blanks up to 80 kg (176 lbs). Equipped with two feeders and automatic reference change systems, this equipment optimizes positioning accuracy, minimizes human error, and ensures operational precision.
RESULTS
The high-tonnage transfer press delivered by Fagor Arrasate resulted in significant productivity improvements for Gestamp. While a G2 press line operates at approximately 8 strokes per minute with 1 or 2 parts per stroke, the new transfer press stamps 2 to 4 parts per stroke at 15 strokes per minute, offering unparalleled efficiency.
Complete automation, including a fully automatic die-change system capable of completing reference changes in under 3 minutes, reduced downtime, labor needs, and occupational risks. These advancements enabled Gestamp to streamline operations, reduce costs, and achieve higher quality and repeatability in production, solidifying Fagor Arrasate’s position as a trusted partner for cutting-edge manufacturing solutions.
TRANSFER PRESSES
With over 30 years of experience and more than 200 references, Fagor Arrasate is a leader in manufacturing fully automated transfer presses, including large presses exceeding 3,500 tons. Leveraging two decades of in-house innovation, we offer advanced automation solutions such as transfer systems and pick-up destackers, ensuring precision, efficiency, and reliability in every project.