Manufacturing
Efficient processes, precise procedures and careful quality control ensure high-quality results and short delivery times.
Process flows
immediately ready to go and efficient
Our internal processes are timed so that we can always guarantee punctual delivery. Our experience and transparent workflows guarantee a timely and routine completion of all custom-made products. Short communication channels, trusting cooperation and a high degree of personal responsibility ensure that our processes run efficiently.
Descaling
Since environmental protection is an important issue at Andernach & Bleck, we use a mechanical process for descaling. The scale layer and the existing rust are removed from the raw material using a mixture of small but different sized steel balls.
Drawing
Drawing is the main process. The previously descaled raw material is cold-formed lengthwise by forming dies (drawing tools).
Depending on its structure, the raw material is either sharpened to allow the bar to be inserted into the die or pushed into the die using hydraulic-mechanical insertion devices. A drawing tong then takes the material from the drawing carriage and pulls it through the drawing tool with the addition of lubricants.
The resulting product is characterized by high dimensional accuracy and homogeneous surfaces.
Straightening
Straightness deviations occur during cold forming due to dimensional fluctuations in the raw material. Andernach & Bleck has roller straightening machines and straightening presses with different pressure forces to produce the straightness deviation required by the customer or described in standards.
Cutting to length
The final mechanical step to complete the cold-formed product is cutting to production or stock lengths. These are between 3 - 4 m and 6 - 7 m. Of course, we are also able to accommodate deviating customer requests if a length other than stock length is required. Depending on the material thickness and required accuracy, cutting to length is carried out using shears, band saws or circular saws. A length tolerance of up to ± 1 mm can be realized.
Chamfering, centering or planning
We offer various end designs for the automated further processing of our round, hexagonal or square bar steel:
- chamfered with standard angles of 30° / 45° / 60° and a described chamfer length (deviating customer requirements can also be realized)
- planned and center drilled
QUALITY ASSURANCE
The first quality control takes place when the raw material is delivered. The delivery documents are checked against the order specifications. If these correspond to the specifications, the material is temporarily stored in the raw material warehouse.
During the entire production process, visual and dimensional checks are carried out as part of the continuous worker self-inspection. In addition, there are complex checks in the quality department:
- Metallographic tests such as purity, microstructure and decarburization tests
- Determination and documentation of mechanical-technological values in tensile tests up to 600 kN, notched bar impact tests with 300 J working capacity, as well as Brinell and Vickers hardness tests
- Non-destructive testing methods such as eddy current testing using rotary probes or differential coil methods as well as ultrasonic, magnetic particle, dye penetration and roughness testing
- Testing of magnetic characteristics
- Testing and comparing the chemical composition with the information provided by the supplier using an emission spectrometermeter