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Forge Production

2

Business of Autocomponents Division

Chassis and Power Train systems

Steering system

Brake system

Fuel system

Driving and non-driving axles

Suspension modules

Clutch

Wheel discs

Leaf springs

Control systems

Body armature

Stamped parts

Truck beds

Frame

Body

Success factors in detail

Tools and accessories

Dies and press-molds

Fasteners

(JV Bulten-GAZ)

Tooling

Joint ventures

Exhaust system

(JV Bosal-GAZ)

Forge

Iron castings

Aluminum and other

non-ferrous casting

Blanking production

One of the largest Forges in RF

A complete technological cycle of die forging

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GAZ JSC

Space, м2

Master forging Shop 34 755

Forging-Press Shop

46 567 Large hot stampings area (line

12500 tf)

Forging –

Press Shop

Master forging

Shop

Large hot

stampings area

(line 12500 tf)

Location forging production

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Forge parts

Production has a complete technological cycle of forgings manufacture

by die forging (including heat treatment, straightening, coining and

scale removal). Blanks for stamping are heated in induction gas and

electric furnaces, direct resistance heating is also applied. Forgings are

normalized, thermally refined and also are subject to isothermal

annealing

• One of the largest Forges in RF

• 1200 items of forging blanks (forgings, pressed

parts) manufactured from constructional and alloyed

steels, АК6 aluminum alloys

Production capabilities

Customers

Forge parts

Forge Quality Management System has been certified for compliance with

State Standard P ISO 9001-2008

Capacities: 110 thou. tons per annum

Wide range of forging equipment:

• Crank hot-forming presses with tonnage ranging from 630 to 6 300

• Automatic line for stamping large parts (based on forging hot stamping

press with tonnage of 12 500 – 2 pcs

• “HATEBUR” AMP-70 series automatic hot stamping press with tonnage of

1 500 – 1 pcs

• EUMUCO automatic lines with tonnage of 3 150 – 2 pcs

• Automatic transverse v-shaped rolling line WRL10025TN-1, 40 tf – 1 pcs

• Horizontal forging machines with tonnage ranging from 250 to 2 000

• Pneumatic die hammers with driver assemblies weighing 1 000 kg - 5 pcs

• Clamping machines for manufacture of steering wheel shaft and tie rods –

4 pcs

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Forge products

Connecting rod and connecting rod caps weighing

from 0,3 to 2 kg

Front axle beams weighing from 26 to 160 kg

Gears of different overall dimensions weighing from 0,8

19 kg

Levers and forks weighing 0,1 to 5 kg

Shafts weighing from 3 to 7 kg

As well as flanges, T-branches, hooks and other

forgings

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50%

2%

AMZ

Nizhny Novgorod Motors,

Technopark

GAZ

3%

KAAZ

2%

ZZGT

2%

Russian Railways

2%

SAAZ

2% UMZ

Other (URAL, PAZ, YAZDA and etc.)

2%

17%

8%

2%

Cooperation

Automobile Plant GAZ

ZMZ

Rosstar

2%

5%

Customer's portfolio

Development of sales to external

customers (outside GAZ Group)

Factors:

- increase of number of OEM in Russia and

localization of forgings production

- increase of forgings production for different

branches of industry

2013

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Equipment of

GAZ Forging

Production

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Technologies

Complete technological cycle of forging production by hot die forging (including heat

treatment, straightening, embossing and scale removal)

Heating of blanks before pressing blanks is made in induction installations, gas

furnaces and electric furnaces, direct resistance heating is also used.

In Forge heat-treatment shop forgings undergo normalizing, thermal refinement and

isothermal annealing

Additional operations – shot-blasting, straightening and embossing

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Automatic line L-6417

Equipment characteristics: 2 lines for pressing of large parts up to 160 kg

Country of origin: Russia (Voronezh)

Forcing: 12 500 tons

Capacity: 40 – 70 pcs/hour

Products: Front axle beams, various crank-shafts

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Hot forming automatic machine “HATEBUR АМР-70”

Equipment characteristic:

Production of forgings:

-Projected diameter up to 147 mm,

-height from 15 to 80 mm,

-Inner diameter of rings at least 25 mm.

Country of origin: “Hatebur” (Switzerland).

Forcing: 1 500 tons

Capacity: 2 400 – 7 200 pcs/hour

Products: Gears, flanges, rings

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“EUMUCO” automatic line

Equipment characteristics:

2 lines consist of press КР 3150, forge-rolling machines and

induction installation for heating of blanks. Production of blanks

weighting from 1 to 3,5 kg and length up to 225 mm.

Country of origin: “Eumuco” (Germany).

Forcing: 3 150 tons

Capacity: 600 pcs/hour

Products: Connecting rods, cylinder and piston parts, levers, yokes, flanges,

cross-pieces

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Transverse v-shaped rolling automatic line

Equipment characteristic:

Production of rolled forgings by method of hot plastic deformation:

-diameter 53-100 mm;

-length 145-500 mm;

-Maximal weight of a blank - 11 kg.

Country of origin: JLLC “ATMengeering” (Belorussia-Minks)

Forcing: 40 tons

Capacity: Pair rolling – 180-400 pcs/hour, single rolling – 90-200 pcs/hour

Products: Shafts, axles

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Other equipment

Crank-type hot forging presses 630-6300 tf

(propeller-shaft yoke, gears, brackets, connecting rods,

flanges, shafts, levers, etc. from 0,3 to 20 kg. Heating of blanks

is done in induction-heating installations)

• Horizontal forging machine from 250 to 2000 tf (gears,

shafts, axle shafts, rear axles from 0,1 to 30 kg, heating of

blanks in gas furnaces)

• Pneumatic drop forging hammer 1 000 kg.

(levers, yokes, etc. from 0,035 to 3 kg. heating of blanks in gas

furnaces)

• Rolling-on machines for production of steering shaft

and steering linkage rod

• Electroforging machines for heading of blanks for

pressworks

• Bending machines for production of stabilizer rods

• Forge-rolling machines

• V-shaped rolling machines

• Trimming and embossing presses.

List of other equipment:

Extra:

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Auxiliary equipment

Control and measuring equipment

Hardness gages (HB) – measurement of products hardness when conducting heat treatment quality

control

Magnetic flow detector (made by CGM company – Italy) – is used for detection of defects in product

material

Laboratory and research equipment

Microscopes OLIMPUS GX51, Japan – are used for metallographic examinations

Tensile testing machines МЕТRОТЕSТ, pendulum testing machines – are used for measuring of ultimate

strength, yield point, impact strength and for testing other mechanical properties of products

X-ray fluorescence spectrometers ARL – are used for chemical examination of materials

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Support production

Production of dies for hot forming,

weight up to 2 tons

Production of various measuring

tools and devices

Die repair technology by weld-on

method

Development of management programs for CNC machines

(CAM System)

Power SHAPE (Delcam)

Power MILL (Delcam)

Work NC

TECHTRAN

Modeling and design (CAD System)

- CATIA V5

- AUTOCAD

- DEFORM

Products

Software

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Quality

Certification

Forgings (Forge)

ISO-9001

Compliance with international standards

Выполнение требований потребителей достигается за счет приведения процессов производства

Дивизиона Автокомпоненты в соответствие со стандартами ISO 9001 и ISO/TS 16949

Company success at the market

Product competitiveness

Rise of the company prestige and status

Build-up of the personnel motivation

Certification plan

Forgings (Forge) 2016

ISO/TS 16949

ISO 14001:2004

BS OHSAS 18001:2007

Certification

GAZ OJSC

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Thank you

for attention!

Lenina Avenue 88, Nizhny Novgorod,

Russia 603004, Tel. +7 (831) 299 09 90,

fax: +7 (831) 290 81 89

Epshteyn Kirill – Director of Autocomponents

Division

e-mail: EpshteynKK@gaz.ru

Alexey Zaytsev– Director for Development

Autocomponents Division

e-mail:ZaytsevAL@gaz.ru

Nikolay Raytsyn - Director for Sales,

Autocomponents Division

e-mail:RaytsynNM@gaz.ru

www.gaz.ru