Technologies
The Cotarko GmbH plant in Cologne currently employs 280 people.
With a production volume of about 30 million parts and material consumption of 54,000 tonnes a year, about 130,000 parts are currently delivered to customers worldwide on a daily basis.
A total of 4 Hatepur forging presses, 3 wedge and 4 ring rollers presses such as 24 machines for machining ensure that around 130,000 forged parts are delivered to our customers worldwide every day.
Technical highlights
1982
Commissioning of the worldwide first Hatebur AMP70L machines for extruded components – Development of the first extruded component for AMP70L
1989
Manufacturing of ,ring gear‘ differential components with an AGW ring rolling machine
1990
Utilization of Smeral ULS 100 cross wedge rolling for transmission shafts
1998
Commissioning of one of the world‘s first Hatebur AMP50XL machines for extruded components
2003
Restructing of plant layout according to the principles of “lean manufacturing”
2005
Start of machining for forging blanks as as an additional process step
2010
Launch of the internal wheel hub manufacturing and assembly line
2021
Launch of our new internal toolshop
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
Name
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
Producing for seamless ring gears
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-press |
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) Wheel hubs (ready-to-install) |
Special features:
- Complete production line for machining, especially in wheel hub production
- Pre-machining of gear wheels and shafts is possible in our company