Examples for production processes for highly stressed parts within automotives are forging, sintering, machining and casting. The amount of stress that a single part can endure is due to the orientation of the fibers. The better the orientation the better the dynamic strength is. Forging shows the best orientation, especially the flashless forging within closed dies. It has no flash that is cut so the fibers are not ripped apart which leads to higher resistance against stress. In this paper the simulation of fiber orientation is described and compared to experimental researches.
flashless precision forging, simulation fiber orientation
Independently many researches have been made in recent years in the nano- and microtechnology and in production technology. Combining both specialties enables the development of new production facilities, such as the multifunction forging which has been researched at IPH – Institut für integrierte Produktion. Here, nanoparticles are deposited on the raw stock and are for lubrication and the quality control; for example a crack detection. The addition of multifunctional nanoparticles saves time and money
nanoparticles, closed die forging
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, forecasting methods regarding the life-cycle costs of tools and moulds were presented as a major focus of current research.
research and development, life-cycle costs, tool and mould making
Sheet metall parts with small dimensions and high quantities are usually manufactured very economically in a progressive forming process. If these parts require welded joining elements, these elements must be joined on separate welding stations. The handling of the separated components causes high costs. The integration of a thermal joining process simplifies the manufacturing of such components significantly. As part of an EFB research project a welding step including welding head and tool supply of the joining components to the tool integrated stud welding process was developed at the IPH. Emissions are removed from the welding area by means of suction while the tool is closed to protect the tool against contamination. To ensure the quality of welding process parameters current, voltage and distance are permanently monitored. Investigations of welding results from long-term tests with introduced disruptive effects showed a high process reliability and sustainability of compounds as well as a stable and reproducible process. Overall, it was shown that a thermal joining process safely integrate in sheet metal forming by stud welding and that potentially occurring disruptive effects are manageable.
sheet metal, capacitor discharge arc stud welding, cd arc stud welding, tip ignition, follow-on tool
An efficient logistic controlling conducting a diagnostic of production logistic with a rule-based expert system can assist companies and in particular small and medium sized enterprises to meet the increasing requirements of the market concerning logistic efficiency. These requirements must, however, be aligned with the company's strategy. Based on the company's strategy a functional strategy has to be derived for the company's logistic to put the superior objectives sustainably into practice. The challenges are the derivation and monitoring of appropriate logistical key indicators that represent the strategic goals, in diagnosing a dysfunction in the production logistic as well as in the derivation of appropriate operational measures to handle the dysfunction and thereby to support the strategy.
logistical controlling, sme, keyindicators
The abrasive cutting with thin diamond tools is a common method for the production of plate-like components, such as tiles, made of hard stone. Hard rocks are suitable as construction materials due to their material properties. They are used for e. g. cladding buildings or interior design. In addition to mining granite rough blocks in quarries especially metal-cutting production lies at the heart of value creation. Alone for the abrasive cutting, which is often referred to in practice as a circular sawing, 67% of the production costs are bound. The reason for this very high cost portion is the ratio of removal volume to board volume of more than 60% leading to a loss of raw material and high tool and energy costs.
abrasive cutting, metal removal rate, metal removal volume
Cyclically interlinked production systems are commonly used production facilities. During the bidding phase manufacturers of these systems assure customers about the performance and operating efficiency despite numerous uncertainties. Up to now, there has been no planning approach that could hedge these results. Recently however, a method for configuring cyclically interlinked production systems during the bidding phase has been developed in order to resolve this deficit. Data mining models are built to predict performance figures of production systems, whereas, characteristic curves are used to predict the operating efficiency of a system configuration. This paper introduces the challenge of bid proposal management and explains the developed method.
planning, production, system
Assuring a high material availability for production is while reducing sourcing costs remains a major logistical challenge for producing companies. Lean economic processes, flexibility and responsiveness - beneficial both for the customer and for the supplier - are characteristics of an excellent customer-supplier relationship. Standard sourcing models offer a field-tested approach for setting up across company boarders processes.
scor, standard sourcing, logistics models
Logistics is a crucial issue for small and medium sized enterprises (SME). This paper deals with logistical concepts for assembly systems. The IPH is currently conducting a project with the aim of developing a method to combine allocation and delivery concepts for assembly systems to increase the logistical efficiency of SME. Via this method SME are able to adapt quickly to changing market environments.
logistical concept, allocation concept, delivery process model, assembly system.
The long-term supply with spare parts is a complex task for manufacturers of high-value capital-investment goods and the solution depends on numerous uncertain criteria. Besides the high amount of spare parts which has to be stored, the supply has to be secured for many years. The market requires a high performance of the supply of spare parts (short delivery times, high flexibility of time and quantity). The manufacturer is anxious to reduce the costs and risks of the supply of spare parts (e. g. storage costs, supply and sales risks). The strategy for the fulfilment of the spare part demand has to be selected from the large quantity of available strategies. The complexity of this selection problem is additionally increased by different specifications of the spare parts, which affect the selection of a strategy. Some of these specifications are the suitability of storage, the quality rating, the percentage of sales of the spare parts and the importance of the spare parts for the customer. In the research project "GET – Geregelte Ersatzteil-Bedarfsdeckungs-Strategien" an approach for the selection and continuous monitoring of strategies for the fulfilment of the spare part demand was developed.
spare parts supply
Today, the forging industry is facing new challenges. The day-to-day business is characterized by fluctuating order quantities and the production of high numbers of variants. Under this condition the tool logistics is gaining more importance in order to minimize production downtimes through guaranteeing high tool availability with minimal tool costs. This paper presents an approach for a synchronisation of tool supply processes to production requirements by evaluation of the cause-effect interdependencies from tool life quantity and tool stock level on production performance and tool utilization.
forging industry, tool logistics, simulation study, cause-effect interdependencies, tool logistics o
This article presents research results concerning the wear behaviour of precision forging dies within the framework of the Collaborative Research Centre (CRC) 489 "Process chain for the manufacturing of precision forged high performance components". The wear behaviour is described in accordance to the wear curve of DIN 31051. Tests within the scope of this CRC have revealed two different kinds of measurable wear, material abrasion and material adhesion. Based on the wear curve of an examined precision forging tool the threshold level of damage is determined. The threshold level of damage complies with the maximal quantity of good parts which can be produced with the precision forging tool. An approach to identify an economic lot size for forging processes taking into account the maximal tool quantity was developed, in order to enable an integrated production planning and tool maintenance planning.
batch size determination, tool life quantity, abrasion behavior, forging industry
Short term and frequent changes of delivery quantities and dates by customers as well as unreliable logistic behaviour of raw material suppliers cause logistic turbulences, which affect the accuracy of production planning and control (PPC). In order to assure more flexible reaction capability in combination with high level reliability of PPC, logistic risk management is essential, which enables an early identification, assessment and control of logistic risks in the supply chain. Within the research project "SFB 489 C4 - design and control of flexible supply chains for the production of precision forged components" a comprehensive approach was developed for the implementation of logistic risk management in PPC in flexible supply chains. This paper describes the developed methods for risk identification, risk assessment and risk control as well.
production planning and -steering, precision forging, tool insert, tool inventory reduction, forging
The guide describes an expert system that allows a person-independent representation and low-resource utilization of production system knowledge. The expert system is designed for the die and mold making industry. Central components of the system are a data model for knowledge representation, a tool shop specifically configured knowledge base and data mining algorithms for automated adaptation of the knowledge base on company-specific constraints.
production system, lean production, expert system, knowledge man-agement, data mining
Even the tool and mold making industry can not afford waste in operational procedures. Designing a lean company is now supported by an expert system of IPH.
production system, lean production, expert system, knowledge management, data mining
function-based method, tender preparation, injection molding
