Preforming is an essential step in flashless forging processes. This paper describes the development of a four stage process chain for flashless forging of a crankshaft with pin and flange. The process consists of cross wedge rolling, lateral extrusion, bi-directional forging and final forming. The finite-element-analysis (FEA) performed with the software Forge 3 and experimental tests are executed with different process parameters, like billet and tool temperature, rolling velocity and steel. To reduce process steps, like lateral extrusion, a direct combination of cross wedge rolling and bidirectional forging is analysed with FEA-software Forge 3 for a one cylinder crankshaft without pin and flange. The results of the FEA give suitable forming angles alpha for cross wedge rolling and several geometric parameters for a modification of the bi-directional tool.
cross wedge rolling, bi-directional forging, crankshaft forging without flash, preforming
By leveraging the production factor "human" it is possible by taking into account human performance fluctuations during the day to reduce product-related defect costs and increase quality. To this end, the integration of human performance variations in methods of production planning and control must be carried out. This article introduces a method by which a quality-oriented job shop schedule can be created, taking into account human performance fluctuations.
produktion planning, job shop scheduling, human performance fluctuation, optimization problem
Will the freight depot still be large enough in ten years – or is it necessary to built new rails? An austrian company wanted an answer to this question – and IPH was able to help with a detailed material flow simulation.
material flow simulation, railway traffic
An analysis of lifecycle data offers the potential to identify product weaknesses and starting points for product innovations. The paper describes a concept to analyze lifecycle data using predefined analyses and interactive searches. Moreover, a concept to integrate the results of the data analysis into an existing software environment is presented.
data-mining, life-cycle-data, data analysis, knowledge akquisition
While definitions already exist for smaller scale device structures e. g. nanotechnology, the conceptual distinction between standard large products and large scale or XXL products is currently insufficient. This study presents a basic definition of large scale products. At first hypotheses are being derived and examined at an empirical study of three sample products threaded nuts, screw presses and passenger aircrafts. It will be shown that the transition from conventional products to XXL large scale products is characterized by a disproportionate increase in the ratio of product costs to the augmentation of a characteristic product’s feature. Based on the results a definition for the characterization of large scale products is established referring to the technical, organizational and economical restraints and to the available processes and tools.
xxl-product, large-scale, xxl, definition
The range of structure sizes for industrial products produced today is increasingly expanding. This trend is evident in both small-scale (e.g. semiconductor applications) and large-scale (e.g. wind turbine rotors) products. While definitions already exist for smaller scale device structures, the conceptual distinction between conventional large products and large scale products is currently insufficient. In this study, we present a potential basis for the definition of large scale products. To achieve this, we derive hypotheses and examine these in the context of an empirical study using the examples of several sample products. It is shown that the transition from conventional products to large scale products is characterized by a disproportionate increase in product costs due to the augmentation of a characteristic product feature. Eventually we derive a proposed definition which characterizes large scale products in the field of production engineering.
xxl-product, large-scale, xxl, definition
Products have historically been subject to continuous development. On the one hand, these are to fix known issues and bugs compared to the original product. On the other hand, companies are forced by globalization to optimize their products globally in order to stay competitive in the market. Such development often involves not only a function of growth, but also needs a development of the geometric dimensions. For Example, the VW Golf has been added more and more safety and comfort features with each generation. In this way, the length of the VW Golf with every model change has increased by an average of 9cm.
xxl products, large-scale products, xxl definition
The systematic analysis of life cycle data provides the potential to identify weaknesses of current products and starting points for product innovations. This paper presents a tool for an automated analysis of life-cycle data and describes the necessary steps of a data analysis. In particular, the merging of data from different systems, the pre-processing of raw data, the data analysis and interpretation are explained. In this context, the pre-processing of free text is described. Moreover, two models for an automated analysis of life cycle data are introduced. Finally, the implementation of this concept into a software tool is described.
software tool, lifecycle, data analysis, data mining, knowledge deployment
An analysis of lifecycle data offers the potential to identify product weaknesses and starting points for product innovations. The paper describes a concept to analyze lifecycle data and declares which partial steps are necessary to collect, preprocess and analyze the data.
software tool, lifecycle, data analysis, data mining, knowledge deployment
The production of titanium parts in small batches using a flexible machine and a fast layout method as well as a temperature and defect measurement were not considered in investigations yet. However the industry using valuable materials showed interest in this technology and the CWR module in order to realize the advantages of the CWR technology for small and medium batch sizes. Therefore a CWR machine for flat wedge tools will be developed in the EU project CoVaForm. The wedge tools used in this project will be designed for rolling titanium and micro-alloyed steel. To help SMEs a software tool will be developed for designing CWR processes. Especially for rolling valuable materials like titanium, the boundary conditions are mostly unknown; therefore pre-tests will be done to get process parameters which will enable a working CWR process. To ensure a defect-free production, a quality control will be developed based on thermography which detects defective parts directly during the rolling operation.
cross wedge rolling, CWR machine, titanium, bainitic grade steel, common rail, hip implant
The production of titanium parts in small batches using a flexible machine and a fast layout method as well as a temperature and defect measurement were not considered in investigations yet. However the industry using valuable materials showed interest in this technology and the CWR module in order to realize the advantages of the CWR technology for small and medium batch sizes. Therefore a CWR machine for flat wedge tools will be developed in the EU project CoVaForm. The wedge tools used in this project will be designed for rolling titanium and micro-alloyed steel. To help SMEs a software tool will be developed for designing CWR processes. Especially for rolling valuable materials like titanium, the boundary conditions are mostly unknown; therefore pre-tests will be done to get process parameters which will enable a working CWR process. To ensure a fault-free production, a quality control will be developed based on thermography which detects faulty parts directly during the rolling operation.
cross wedge rolling, CWR machine, titanium, bainitic grade steel, common rail, hip implant
Unlike current production and transport systems the human being has the ability to adapt to physical changes in the workplace as well as organizational changes of the workflow. The aim of the research project " FTF out-of -the-box " is to empower fork lift trucks through cognitive technologies to autonomously handle tasks in logistic processes and execute them independently. Transport orders are given by voice and gesture control. To implement such an interactive autonomous guided vehicle ( AGV) a distributed intelligence to optimize its behavior independently and flexibly by adapting to changing production environments is needed.
driverless transport systems, cognition,production systems, flow of information, human-machine inter
Automated guided vehicle systems (AGVS) basically consist of a control station, a communication system and automated guided vehicles (AGV). Control of the AGVS has the task to carry out a transport order once it is issued by a higher level system. The transport order is implemented by the AGVS-control in an actual movement of the AGV. The number of AGV varies between a few up to 100 AGV. Due to the high number of AGV the likelihood of distraction in the route network increases. Todays central AGVS controls take into account the dynamic and evolving traffic situations inadequately and are insufficiently robust and flexible in terms of changes and disturbances .
agv, decentralzied control, automated guided vehicles
By increasing the height of wind turbine generators the usable wind energy increases exponentially. However, tower weight increases accordingly. Current tower designs limit the tower height due to the explained correlation. The application of lightweight design concepts can lead to a significant weight reduction at comparable tower stiffness. As part of a research project, lightweight design concepts have been developed. These design concepts allow a mass reduction for onshore wind turbine towers up to 20 %. In this paper, the development and results regarding these lightweight concepts are presented.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
The utilization of lightweight engineering methods for tower construction of wind turbine generators enables a weight reduction at constant stiffness. Thus an increase of the tower’s height can be achieved, while keeping its weight. Within a research project at IPH several lightweight engineering solutions from bionical, aviation and aerospace applications have been investigated. According to the developed guidelines a lightweight concept based on trapezoidal sheets can reduce the mass of a 3 MW generator of 90 m height by 20 %. In this article certain details of the construction are being presented.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
Schedule variances in the cycle of field assembly often cause high unplanned costs. This is particularly true for capital-intensive, large-scale products. Currently no model exists which supports cost determination already during planning, implementation or after assembly. Thus, comprehensive logistics controlling is not possible which prevents high schedule adherence and low logistics costs even on the occurrence of disruptions. In this paper, a research project is presented, which has the goal of developing a method by which a deadline- and cost controlling of the material availability for the assembly of wind turbines can be secured.
material provisioning, site assembly, cost controlling, schedule deviation, early warning system, fo
In modern business, the efficient use of resources, the optimization of processes and managing costs are key competitive factors. In the metal forming industry the pressure of competition is constantly increasing and the implementation of these competitive factors is important for staying in business. The increasing prices for energy and steel because the manufacturers to reduce these cost factors. With research activities even SME’s are able to improve their quality, for example by using warm forging processes. To keep the costs in a low level a reduction of the used material is necessary. Due to this aim, flashless preforming operations for a two cylinder crankshaft were developed. But the challenges are very long simulation and development time for designing the preforming dies. Further a highly qualified die steel material is required for complex preforming dies.
closed die forging, multididrectional forging, process chain, resource efficiency
The customer-oriented individual production, as part of the future project "Industry 4.0", is based on the progressive shortening of development cycles. The parallel to the material flow directed flow of information gains in importance for a decentralized material flow control. The use of this newly available information through the production systems requires cognitive abilities on the machines. For this future machines as well as handling and transport systems should communicate, identify problems, make their own conclusions, learn and plan. For this purpose cyber physical production systems are the technological foundation.
cyber-physical production systems, individual production, intelligent networking
Planning ahead, make decisions and adapt flexibly to new situations: What is natural for people should now learn machines. That is the aim of the industrial 4.0 project netkoPs, which developed together by ITA and IPH.
cyber-physical production systems, individual production, intelligent networking
Increasingly demanding markets and reduced production depths force manufacturers of complex products to better coordinate supply processes for assembly. In this article a research project is presented which aims to develop a control procedure for companies to react on delivery date deviations in supply processes. Particularly, as companies act as part of a network, a reasonable behavior in that perspective is sought.
company networks, simulation, supply processes, supply chain management, cooperation
