Production Plant
1. Raw Material
Billet material, which is delivered in bars, is stored separately and according to dimension. The materials are released for production based on mill certificates and internal quality checks.
2. Billet cutting
The individual bars of raw material are cut to the correct lengths depending on cylinder size. The cut blocks are then placed on metal pallets which are clearly marked with order and identification heat numbers.
3. Hot Forging
The cut blocks are charged into a furnace with controlled atmosphere where they are heated to forging temperature. After the heating, the piercing press forms a tubular body called "tubus". After that, the "tubus" enters a draw press, in which the wall thickness is reduced to the required value and stretched to length. The trimming of the cylinder length is carried out in specially devised cutting equipment.
4. Neck Spinning
After heating the open end in an inductive furnace, the necks are formed in special spinning machines. In order to maintain the forging temperature during the spinning operation, additional heat is supplied by means of a gas burner.
5. Heat Treatment
In order to achieve the mechanical values, the cylinders are introduced into a furnace horizontally, and, at the end of this process, dipped into a quenching bath. A controlled cooling follows in the quenching bath which leads to a change of steel structure and a very hard microstructure. After the hardening the cylinders go through a tempering process which give the steel the required properties.
6. Hardness Testing
Following the heat treatment process, the cylinders are shot blasted and then tested for the correct hardness.
7. Machining of Necks and mounting of Neck Rings
Following on, the cylinder necks are machined and threaded automatically, and, where necessary, a neck ring mounted. Subsequently, the cooling lubricant together with metal shavings are removed.
8. Surface Control / Ultrasonic Testing
During surface control, threads are checked once again and both the internal and external surfaces checked for defects. If stipulated, an ultrasonic test on the cylindrical part will be carried out for longitudinal and transverse defects.
9. Hydraulic Testing
In order to fulfill safety guidelines all cylinders are pressure tested at test pressure. The cylinders weights and water capacities are determined simultaneously. The variable as well as fix data are punched into the shoulder area in the following working stage.
10. Painting (Longlife Powercoat System) and Valving
Prior to painting, cylinders are internally shot blasted and then painted according to customer’s wish. Accessories such as valves and protective caps are then mounted.
11. Packing
The finished cylinders are packed on pallets and made ready for dispatch
Billet material, which is delivered in bars, is stored separately and according to dimension. The materials are released for production based on mill certificates and internal quality checks.
2. Billet cutting
The individual bars of raw material are cut to the correct lengths depending on cylinder size. The cut blocks are then placed on metal pallets which are clearly marked with order and identification heat numbers.
3. Hot Forging
The cut blocks are charged into a furnace with controlled atmosphere where they are heated to forging temperature. After the heating, the piercing press forms a tubular body called "tubus". After that, the "tubus" enters a draw press, in which the wall thickness is reduced to the required value and stretched to length. The trimming of the cylinder length is carried out in specially devised cutting equipment.
4. Neck Spinning
After heating the open end in an inductive furnace, the necks are formed in special spinning machines. In order to maintain the forging temperature during the spinning operation, additional heat is supplied by means of a gas burner.
5. Heat Treatment
In order to achieve the mechanical values, the cylinders are introduced into a furnace horizontally, and, at the end of this process, dipped into a quenching bath. A controlled cooling follows in the quenching bath which leads to a change of steel structure and a very hard microstructure. After the hardening the cylinders go through a tempering process which give the steel the required properties.
6. Hardness Testing
Following the heat treatment process, the cylinders are shot blasted and then tested for the correct hardness.
7. Machining of Necks and mounting of Neck Rings
Following on, the cylinder necks are machined and threaded automatically, and, where necessary, a neck ring mounted. Subsequently, the cooling lubricant together with metal shavings are removed.
8. Surface Control / Ultrasonic Testing
During surface control, threads are checked once again and both the internal and external surfaces checked for defects. If stipulated, an ultrasonic test on the cylindrical part will be carried out for longitudinal and transverse defects.
9. Hydraulic Testing
In order to fulfill safety guidelines all cylinders are pressure tested at test pressure. The cylinders weights and water capacities are determined simultaneously. The variable as well as fix data are punched into the shoulder area in the following working stage.
10. Painting (Longlife Powercoat System) and Valving
Prior to painting, cylinders are internally shot blasted and then painted according to customer’s wish. Accessories such as valves and protective caps are then mounted.
11. Packing
The finished cylinders are packed on pallets and made ready for dispatch
Worthington Cylinders GmbH's excellence
- Six Sigma
- BRI (Behaviour Risk Improvement)
- Kaizen
- TPM (Total Productive Maintenance)
- ISO 9001 certification (Quality)
- ISO 14000 certification (Environment)
- ISO TS16949 certification (Automotive)
- EFQM
- Great Place to Work Award
