In the forging industry, cross wedge rolling is a well-established process for production of cylindrical pre-forms with a highly efficient material utilization. To prevent the appearance of material defects during forming, the wedge geometry of the tools is adjusted to the designated pre-form. Today, cross wedge rolling is executed within the hot temperature range. To analyze warm cross wedge rolling, the scientists at IPH - Institut für Integrierte Produktion gemeinnützige GmbH developed a test site for cross wedge rolling experiments.
warm forging, process chain, cross wedge rolling
Cross wedge rolling is used today in the hot temperature range. A test stand for cross wedge rolling tests was developed by the IPH - Institute of Integrated Production to examine this process even with warm component temperatures. The developed test rig for CWR allows practical examination of the influence of different workpiece and tool temperatures, tool geometries and rolling speeds on the forming result. The results of the practical experiments will give insight on customized design of wedge tool geometries, forming velocities as well as tool temperatures for warm and hot cross wedge rolling. Within the project DeVaPro the test rig makes an important contribution to the implementation of a complete custom made technical process chain in warm temperature range.
warm forging, process chain, cross wedge rolling
Warm forged parts have advantages in comparison to conventional hot forged parts: Closer tolerances, reduced surface roughness, no scale and reduced decarburization. However, the geometrical spectrum of warm forged parts is restricted by high flow stress. To overcome this geometrical limitation new rolling and forging processes are developed in the European research project "DeVaPro - Development of a Variable Warm Forging Process Chain". The focus is on the layout of a warm preforming operation by cross wedge rolling followed by an intermediate heating and warm final forming in conventional dies. To get an idea of the effect of lower temperatures on process parameters, e.g. force, die wear and microstructure as opposed to hot forging processes, FE-simulations and experimental tests with a model are performed. In this paper a new warm cross wedge rolling process is introduced and results of experimental tests e. g. mechanical characteristics and microstructure are shown.
warm forging, process chain, cross wedge rolling
To overcome the geometrical limitation of warm forging, in the European research project "DeVaPro - Development of a Variable warm forging Process chain" new rolling and forging processes are developed. The aim of the project is to develop a warm forging process chain by selecting the best suitable hot preforming technology to obtain the desired mass distribution before warm forging. The technology will be adapted to the specific requirements of warm forming. A warm rolling operation and an induction reheating process will be introduced within this project. A steering link and a connecting rod are used as sample parts.
warm forging, process chain, cross wedge rolling
Reducing the process steps, the number of tools and the needed amount of material are the main advantages of combining flashless forming with punching of forged parts. This process was designed at IPH – Institut für integrierte Produktion Hannover. Even the post-processing is reduced drastically because the tolerances are sufficient for most of the applications. The ressearchers developed one tool concept for two different parts. The first is close to a gear wheel and rotationally symmetric, the second is an elongated geometry. Finally the innovative tool concept was successfully tested
flashless precision forging, punching, tool design
Many forged construction components, such as conrods or ring spanners, have hollow cavities, holes or breaks, which are made in a further process step, usually by hot punching. A combined forging and punching method developed by the Institut für Integrierte Produktion Hannover gemeinnützige GmbH (IPH-Hanover Institute for Integrated Production, non profit company) enables the integration of the punching into the precision forming process.
flashless precision forging, punching, tool design
Flashless precision forging is a high quality process which is used to produce near net shape forgings in the tolerance class from IT 8 to IT 10. Representative parts produced by this process are gear-wheels or joint heads. Many forged parts have drillings e.g. as bearing surfaces. These parts are produced in two separate processes: forging and the through hole piercing process. Scope of a research project of the IPH - Institute of Integrated Production Hannover is to realize the combination of the two processes into one flashless precision forging process. Example parts are a rotation-symmetric part similar to gear-wheels and a part with a distinct longitudinal axis which is similar to joint heads. For both parts the forging process was simulated and forged on a screw press. It was shown that a combined forging/piercing process is feasible. Further investigations of the microstructure and the quality of the drilling surfaces of both parts are planned for comparison.
flashless precision forging, punching, tool design
Resources and cost efficiency as well as process optimisation are key factors in today’s market. The competition pressure in forging industry is increasing steadily. Today, parts with openings, cut outs or something similar are punched and partially deburred in hot state after the actual forging process. The combination of forging and punching in one process offers the opportunity to save money and time.
flashless precision forging, punching, tool design
Many forged parts have drillings e.g. as bearing surfaces. These parts are produced in two separate processes: forging and the through hole piercing process. Scope of a research project of the IPH - Institute of Integrated Production Hannover is to realize the combination of the two processes into one flashless precision forging process. This combination lowers the process time, the amount of raw material and the number of tools and faults. Example parts are a rotation-symmetric part similar to gear-wheels and a part with a distinct longitudinal axis which is similar to joint heads. For both parts the forging process was simulated and forged on a screw press. It was shown that a combined forging/piercing process is feasible. Further investigations of the microstructure and the quality of the drilling surfaces of both parts are planned for comparison
flashless precision forging, punching, tool design
Efficiency, reducing costs and optimization are important factors for companys. Achieving this means to reduce the amount of raw material, production time and production steps. IPH – Institut für integrierte Produktion Hannover has developed a combined process for piecing and flashless forging that shortens the number of steps within the process. This new operation is suitable for rotation-symmetric parts as well as for elongated parts. Combing forging and piercing leads to less requirement of raw material and a shortend process time. This was successfully testesd at IPH.
flashless precision forging, punching, tool design
The cross linking of companies on turbulent Markets cause an increasing dynamic in individualized productions and places high requirements on software applications which are used within companies. The availability of necessary data across company borders within production networks through an interlinking of applications is only one challenge, applications are facing in order to achieve a high level of process transparency.
mes, erp, shop floor, process transparency, supply chain
Warm forged parts are distinguished by good surface properties and high dimensional accuracy. In comparison to hot forging the maindisadvantage is the high wear of the forging dies because of the higher mechanical load. Diamond-Like Carbon (DLC) coatings are anti-adhesive and extremely hard (up to 3500 HV) and are thus suitable as wear protection coatings. The suitability of these kind of coating is examined by simulation and experiments at the IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH. For this purpose, a modular test rig was developed, which enables the detection of relevant process parameters, e.g. as the die temperature. The project aims at a reduction of die wear and a wa to demonstrate the wear process, depending on the process parameters.
DLC, coating, warm forging
For the forging process, semi-finished steel products are predominantly manufactured by shearing bar stock. However, the geometry and volume accuracy of sheared sections of bar stock, due to shearing errors, is inadequate for some forming processes, in particular for precision forging. Hence, it is necessary to optimize the shearing process. By an oscillating movement of the shearing blade, the shearing surface quality can be improved, thereby increasing the accuracy of the geometry and the volume.
billet shear, forging, swinging
Quality requirments are demanding wear protection for forging dies to ensure a long life time in combination with dimensional accuracy. This paper describes the investigation of yet unknown coatings in the forging industry like laser based hard coatings and diamond like carbon coatings.
aluminium forging, wear, wear coatings
The complaint processing in the customer-supplier relationship is costly and time consuming and often incorrect. At the Institute of Metal Forming and Metal Forming Machine Tool (IFUM) will together with the IPH - Institute of Integrated Production Hannover gGmbH developed a measurement and evaluation system to improve the quality and reduce costs in the processing of complaints involving the 8D method.
processing of complaints, method of valuation, cost reduction, 8d report
The processing of complaints involving the 8D method is sometimes very costly and time consuming and often error-prone. Against this background, an automated metric system for measuring and evaluating the quality of processing of an 8D report is presented in the article. On the one hand text mining algorithms are used to determine the metrics. On the other hand manual reviews are used to realize the required bandwidth at reviews efficiently and reliably. The metric system was implemented in software and is designed to enable companies in various industries to reduce the expense of an effective fault management significantly, to shorten response times in the event of a complaint and to benefit from a long-term avoidance of errors.
quality management, complaint management, 8d report, data mining, text mining
For more than 22 years, IPH has been researching and developing in the field of production technology. What are the company's plans for the future?
This article describes the logistic challenges of producing in networks. Followed by a definition of a production network, the greatest chances as well as the potential risks of producing in networks are identified. The unique features and requirements of network production in comparison with single enterprise production are pointed out and the production logistic research need is derived.
production, production networks, logistics, xxl-products
Short-term, considerable need rises in the production require short-term capacity rises by capacity flexibility which is connected with a reaction time. In the context of a project sponsored by the German research council a possibility has been developed to bridge the reaction time by a short-term, article general reduction of outputs.
ability to deliver, lot size, production planning and control, capacity flexibility
In comparison with the conventional forging with flash, precision forging helps to reduce the amount of raw material. Beyond this no additional step for flash removal is needed. In this paper the development of a three step process for a two cylinder crankshaft with flange and pin is described and afterwards compared to a four step process. It shows that the three step process lowers the number of faults saves time and forces. These advantages are due to the innovative tool concept which is shown in this paper.
cross wedge rolling, bi-directional forging, crankshaft forging without flash
