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
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
Industry 4.0, Tool- and Mold-Making, Forming technology, Artificial Intelligence
Behrens, B.-A.; Faßnacht, P.; Meyer, M.; Nickel, R.: Evolution (in) der Stadienauslegung - Anwendung von evolutionären Algorithmen zum Entwerfen von optimalen Vorformstufen. In: Umformtechnik, Meisenbach Verlag, 43. Jg. (2009), H. 1, S. 20-21.
Tool- and Mold-Making, Forming technology
Behrens, B.-A.; Nickel, R.; Müller, S.: Flashless precision forging of a two-cylinder crankshaft. In: Production Engineering, Springer Verlag Berlin, vol. 3, no. 4 (2009), pp. 381-389.
Tool- and Mold-Making, Forming technology
Behrens, B.-A.; Odening, D.; Müller, S.; Lücke, M.: Process Design and Tooling Configuration for Precision Forging of High Performance Components. In: steel research int., vol. 80, no. 12 (2009), pp. 869-877.
XXL products
Behrens, B.-A.; Overmeyer, L.; Nyhuis, P.; Nickel, R.: XXL-Produkte – ein Trend in der Produktionstechnik. In: VDI-Z Integrierte Produktion, Springer VDI Verlag, 151. Jg. (2009), H.7/8, S. 56-58.
Kerkeling, J.; Müller, K.; Behrens, B.-A.: Prozessketten beim Warmlochen von geschmiedeten Bauteilen verkürzen. In: Intelligenter Produzieren, VDMA Verlag GmbH, o. Jg (2009), H 6, S. 38f.
Meyer, M.; Nickel, R.; Behrens, B.-A.: Einflüsse der Gesenkschmiede-Prozessparameter auf die dynamische Belastbarkeit von Bauteilen aus dem Werkstoff C45 im Dauerschwingversuch. In: HTM - Journal of Heat Treatment and Materials, Carl Hanser Verlag München, 64. Jg. (2009), H. 6, S. 370-375.
Industry 4.0, Tool- and Mold-Making
Behrens, B.-A.: Intelligente Umformwerkzeuge.In: Behrens, B.-A.; Nyhuis, P.; Overmeyer, L.; Nickel, R. (Hrsg.): Innovationen für die Produktionstechnik aus Niedersachsen. IPH, Hannover 2008, S. 81-100.
Forming technology
Behrens, B.-A.; Lau, P.: Key Performance Indicators for Sheet Metal Forming Processes. In: Production Engineering, Springer Verlag Berlin, 2. Jg. (2008), H. 1, S. 73-78.
Production planning
Behrens, B.-A.; Nyhuis, P.; Overmeyer, L.; Nickel, R. (Hrsg.): Innovationen für die Produktionstechnik aus Niedersachsen. IPH, Hannover 2008.
Tool- and Mold-Making
Behrens, B.-A.; Suchmann, P.; Schott, A.: Warm forging: new forming sequence for the manufacturing of long flat pieces. In: Production Engineering, Springer Verlag Berlin, 2. Jg. (2008), H. 2, Nr. 3, S. 261-268.
Production planning
Nickel, R.: Perspektiven der Produktionstechnik am IPH. In: Behrens, B.-A.; Nyhuis, P.; Overmeyer, L.; Nickel, R. (Hrsg.): Innovationen für die Produktionstechnik aus Niedersachsen. IPH, Hannover 2008, S. 21-26.
Production planning
Nyhuis, P.: Globales Varianten Produktionssystem. In: Behrens, B.-A.; Nyhuis, P.; Overmeyer, L.; Nickel, R. (Hrsg.): Innovationen für die Produktionstechnik aus Niedersachsen. IPH, Hannover 2008, S. 59-72.
Industry 4.0
Overmeyer, L.: Plagiatschutz in der Produktion. In: Behrens, B.-A.; Nyhuis, P.; Overmeyer, L.; Nickel, R. (Hrsg.): Innovationen für die Produktionstechnik aus Niedersachsen. IPH, Hannover 2008, S. 45-58.
Production planning
Tönshoff, H. K.: IPH – für Wertschöpfung in Niedersachsen. In: Behrens, B.-A.; Nyhuis, P.; Overmeyer, L.; Nickel, R. (Hrsg.): Innovationen für die Produktionstechnik aus Niedersachsen. IPH, Hannover 2008, S. 7-20.
Tool- and Mold-Making, Forming technology
Behrens, B.-A.; Doege, E.; Reinsch, S.; Telkamp, K.; Dähndel, H.; Specker, A.: Precision Forging Processes for High-Duty Automotive Components. In: Journal of Materials Processing Technology, Elsevier Verlag, vol. 185 (2007), no. 1-3, pp. 139-146.
Tool- and Mold-Making, Forming technology
Behrens, B.-A.; Lau, P.; Wilde, I.: Gratloses Präzisionsschmieden von Langteilen - Ergebnisse einer Wirtschaftlichkeitsstudie. In: ZWF - Zeitschrift für den wirtschaftlichen Fabrikbetrieb, Hanser Verlag München, 102. Jg. (2007), H. 12, S. 862-866.
Forming technology
Behrens, B.-A.; Lüken, I.; Odening, D.; Bistron, M.; Müller, S.; Schott, A.: Forschungstrends in der Warmmassivumformung. In: 2. Massivumformung: Produkte – Partner – Perspektiven 2007, 7. Tagung, VDI-Gesellschaft Produktionstechnik, Industrieverband Massivumformung. 26.-27. September 2007, Leonberg, S. 71-82.
Forming technology
Behrens, B.-A.; Nickel, R.; Lau, P.: Auswahl und Optimierung von Prozessketten für den Bereich Blechumformung. 1. Aufl., Europäische Forschungsgesellschaft für Blechverarbeitung, Hannover 2007.
