Technologies
The Cotarko GmbH plant in Cologne currently employs 220 people.
With a processed material consumption of 41,000 tons of steel per year, a production volume of approx. 40 million parts per year is manufactured.
A total of 4 Hatebur forging presses, 3 wedge rolls and 4 ring rolls as well as 24 machines for machining ensure that approx. 130,000 forged parts are delivered to our customers worldwide every day.
Technical highlights
1982
Commissioning of the world’s first Hatebur AMP 70L press for impact extrusion parts – development of the first impact extrusion part for an AMP70L
1989
Commissioning of the first generation of axial die rolls for the production of “near-net-shape” differential gears
1990
Commissioning of a Smeral ULS 100 cross wedge roll for the production of finished gear shaft blanks
1998
Commissioning of the world’s first Hatebur AMP 50XL press for impact extrusion parts
2003
Restructuring of the plant according to the principles of “lean manufacturing“
2005
Start of machining of forged blanks as an additional process step
2010
Commissioning of the wheel hub production and assembly line
2021
Investment in a new internal tool shop
Fast forging presses
High-tech industrial forge for precision forgings
The forging of steel parts is carried out in the temperature range from 1100°C – 1250°C. The bar stock is heated inductively to the suitable forging temperature, sheared in the Hatebur and then pressed in four forming stages. In the through-feed process it is possible to carry out controlled cooling from the forging heat.
Machinery: Hatebur
|
Designation
Forming stages |
AMP 50 (XL)
4 |
AMP 70 (L)
|
Special features:
- The AMP70 has an 180 mm ejector stroke for extruded parts
- Extruded parts can also be produced on the AMP50
Wedge rolling
Producing for gear shafts
Compression forming of rotationally symmetrical blanks at 1100°C – 1250°C between counter-rotating moving generating tools, which reduce by rolling on the surface of the workpiece. Preferred process for manufacturing gear shafts with widely diverging geometrical cross-sections.
Machinery: Smeral wedge rolling
|
Number Roller diameter |
3 machines 1000 mm |
Special features:
- Forming with undercuts is possible in this process
- Distortion after machining (hardening) is low
- Homogeneous grain flow through whole shaft
Ring rolling
Production of seamless ringears
The ring roller process is realised as a combination process in the temperature range of 1100°C – 1250°C. A process combination of blocking and radial and axial rolling permits seamless production of complex ring gears for the gear differential.
Machinery: maxi-press, multi-pin radial roller and axial die-forging roller
| Number
Maxi presses |
3 machines
16000 kN |
Special features:
- Rolling blanks can be designed with low allowance as finished part
- Especially good surface quality through rolling process
- Unfinished surfaces = finished surfaces can be taken into account on the product
- Environmentally friendly process thanks to low material use
Heat treatment
Different treatment processes according to your specifications
The workpieces are heated slowly and thoroughly in all annealing processes. The various processes which serve to set the desired material properties for use or prepare for subsequent processing (forming or machining) differ through:
- Annealing temperature
- Annealing duration
- Type of cooling
- Sequence of different heat treatment steps
The component characteristics regarding hardness, strength and grain spacing quality are guaranteed by the various heat treatment processes in cooperation with our customers. We can offer the following processes:
- Normalising
- Quenching and tempering
- Annealing
- BG-annealing
- Controlled cooling from forge heat
Mechanical processing
Complete production line for machining
Under certain circumstances, the stage in the process chain at the end of which the precision part the customer wants is ready, may not yet have been reached with the various forming technologies. For this reason, Cotarko has made large investments in machining processing technology.
Machinery: Emag, Rasoma, Karl Klink, Chiron
| Number
Products Technologies |
24 machines
Gear wheels (pre-machining) Turning, broaching, drilling, |
Special features:
- Complete production line for machining, especially in wheel hub production
- Pre-machining of gear wheels and shafts is possible in our company