Case Studies – Jung Werkzeugbau GmbH.

Case Study

WE PUT EVEN
LEGENDS ON A
MORE EFFICIENT TRACK.

An automotive brand based in Stuttgart, Germany, is one of the most sought-after in the world – and not just because of its legendary three-digit model. Since 2009, the company has been producing luxury station wagons and shooting brakes with front-mounted engines. These models differ not only in size and engine capacity. They also come in four- and six-door long-wheelbase versions, which are manufactured separately by a supplier.

Our initial idea was to use a single tool to produce the identical and merely mirror-inverted doors in one operation. The basis for a successful implementation was the combination of the individual parts and the component production on one forming tool.

The project was successful – the manufacturer then back-injected the entire component and separated it into the two individual doors using milling technology.

Our second idea: We asked ourselves whether there was a technical approach to integrating the customer’s existing guillotine shear into the process in such a way that it would have a cost-reducing effect. Our answer: yes. If the customer inserts a single rectangular board and cuts it with the guillotine shear, they don’t need a separate blanking tool. What we had to do for this: “Simply” design the forming process so that this rectangular blank would work.

By the way: It is part of our self-image that we do not “sell” the recommendation for a process optimization as an idea. This is what happened with this customer. As a result, he combined components and tools differently. And he has been saving raw materials ever since. That benefits him and makes us happy!

Case Study

DON’T BE AFRAID TO
CHANGE LOCATIONS:
THAT’S THE WAY TO GO.

DON’T BE AFRAID TO CHANGE LOCATIONS: THAT’S THE WAY TO GO.

The most expensive tools in the world are those that cannot perform due to defects, machine breakdowns or, for example, relocation of production. The latter happened recently when a company went out of business. Production of the components was taken over by another supplier, but the specially developed tools did not fit the production processes of the new supplier. There was a risk of shutdowns and production stoppages at the car manufacturer.

Our idea: We dismantle, rebuild and repair the required 18 tool sets while production continued. Assembly was then to take place at the new customer’s site.

The special feature: the transfer of the tools from the old to the new manufacturer and the rebuild were to be carried out again in parallel with production and successively – including trial runs and test series.

The plan worked: Within 4 months, all tool sets were adapted to the new supplier’s systems, repaired where necessary and installed in the systems. The customer did not have to interrupt component production and the car manufacturer was able to continue production.

We were pleased to be able to help even under extreme time pressure, thanks to our high level of in-house production. Made in Ötigheim.

Case Study

IT’S ALL ABOUT TEAMWORK:
FROM A HAND SKETCH
TO A HIGH-PRECISION TOOL.

IT’S ALL ABOUT TEAMWORK: FROM A HAND SKETCH TO A HIGH-PRECISION TOOL.

When you hear the name Gesmex Exchangers GmbH, you think mainly of heat exchangers. In cooperation with this customer, we developed a novel process for nitrogen synthesis.

Our idea: Gesmex Exchangers brings our experts on board and combines the best of both worlds in the heart of such a plant – the heat exchanger plate. We started with a rough hand sketch from the Gesmex process engineer. Based on this, we developed a clean design of the plate using our 3D CAD system. We also ran a forming and flow simulation.

The result: In the next step, we used this data to create the geometry of the plate, which we also optimized for feasibility and adapted to the expected subsequent thermal processes.

On this basis, we developed and manufactured the appropriate embossing tool. The final tests and the first components immediately showed that Gesmex had chosen the right partner.

Case Study

WE BRING TOGETHER WHAT
BELONGS TOGETHER:
TOOLS AND MATERIALS.

WE BRING TOGETHER WHAT BELONGS TOGETHER: TOOLS AND MATERIALS.

One man’s sorrow is another man’s joy. Mono Group received an order from Jaguar Land Rover to produce aluminum trim parts for the Range Rover SV.

The problem: Even after a year of testing, the quality of the outsourced forming tools was still so poor that it would not meet the premium brand’s high quality standards.

The solution: Don’t invest any more time in further troubleshooting and look for a new service provider right away. This is where Jung Werkzeugbau came in. We built the prototype tool and simulated various tool and material pairings.

The target configuration presented to the customer delivered such good component results that we were immediately able to focus on the upcoming steps, such as the final conversion of the prototype tool based on the simulations.

Case Study

A NICE STORY:
US AND THE MPC
(MULTIPOINT-CONTROL SYSTEM).

Uniform forces are good – but not always! In the conventional process, for example, the sheet metal is held in place by a drawing cushion or the press ram. The problem here is that the force can only be applied uniformly over the entire component. Anything that needs to be done at a specific point requires laborious manual work, such as placing shims under the drawing ring. And that’s not all: if parameters such as the raw material or the ambient conditions change, time-consuming readjustment is called for again. That takes time.

At some point , this became too much for the former managing director, Dr.-Ing Klaus-Jürgen Pahl. With the goal of speeding up the process and improving the overall procedure, he developed the MPC multi-point drawing system especially for hydraulic presses and for use in stainless steel forming.

The idea: to develop a technology in which the cylinders are used at the critical points of the component circumference in order to influence force, path and time exactly there and thus to be able to control the process completely.

The project succeeded. And secured many benefits for customers around the world:

Optimum process control through adapted local force effect
High product flexibility – one MPC unit for the entire product range
Easy tool change without adapting the force transmission elements
Minimal set-up time due to stored setup parameters in the press control system
Lower scrap rates due to fast response to varying material properties

Many of our customers still associate Jung with tools for deep-drawn stainless steel components such as kitchen sinks. It is clear that the Dieffenbacher MPC, in combination with our tools, has enjoyed more than 20 years of success.

Case Study

FOR ONE OF THE LEADING
CAR BRANDS: FROM
ÖTIGHEIM TO MEXICO.

FOR ONE OF THE LEADING CAR BRANDS: FROM ÖTIGHEIM TO MEXICO.

Acting sustainably is an important issue for us as a tool manufacturer! This makes us all the more pleased that we are increasingly getting the chance to work with pioneers in the field of e-mobility. We were brought on board by a supplier with whom we have had a trusting and cooperative relationship for some time. They were recently commissioned to produce the aluminum trim parts for a new e-model. Our part: the tools. We are particularly pleased that we can already contribute our expertise in component and concept development.

Our task: We simulate and develop and use our knowledge to design and shape the components in such a way that process-reliable production is possible. Based on the knowledge gained, we plan the forming process and define the parameters for the required production machines for our partner. If we manage the development phase as well as we have done in the past, we are in the best position to manufacture the series tools and to accompany both the tool start-up and the employee training at the production site in Mexico. We are therefore currently in dialogue with colleagues in Germany, the USA and Mexico.