The quality of molded products and production cycle times are influenced by mold temperature control systems. Today experienced technical designers are developing form-fitting temperature control systems manually. Afterwards they analyzes the systems in iterative and experimental simulations. Here, a method for automatic design of mold temperature control systems is presented. The method uses nature-inspired algorithms, which improve the economical benefit of the construction process and the injection molding process.
injection molding, conformal cooling systems, design, nature-inspired algorithms
Enlarging the height of wind turbine generators leads to exponential increase of the usable wind energy. However the construction’s weight increases equally. Therefore a systematic approach to design lightweight towers for onshore wind turbine generators has been developed in a research project. Different concepts of bionic, aerospace and automotive origin have been used to create lightweight structures for the towers. These lightweight towers have been analyzed by FEA simulations e. g. regarding their fatigue stress. The investigation’s result is a lightweight structure which enables to build wind turbine generator towers of lower wall thickness. Thus a weight reduction up to 20 % can be achieved in comparison to standard towers.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
Transport and storage systems have become extremely efficient because of a high degree of automation. Unfortunately flexibility is lost, because modifications of the systems are very complex. This discrepancy should be resolved in the research project "ISI-WALK". Logistic systems will be designed flexibly and efficiently with use of intelligent interfaces.
logistics, flexibility, interfaces
Production downtimes and maintenance costs affect the choice of an economic maintenance strategy. Predictive maintenance of machines promises a solution for both interests, when machine conditions can be predicted. The digital machine file supports this task by a combination of data exchange and artificial intelligence.
condition monitoring, artificial intelligence
In the project "Increase of maintenance quality through machine-specific information on the example of paper and print finishing" researchers developed methods for an improved maintenance quality by using a predictive strategy. The developed methods combine the exchange of data related to the maintenance with analysis of this data with the help of artificial intelligence. This ensures that the companies that are involved in the lifecycle of a machine gain additional information, for example about the current degree of wear of a unit.
maintenance, data mining
Cross wedge rolling is a method for reshaping cylindrical billets for getting a better mass distribution. Against the backdrop of rising material costs, this method is increasingly becoming the focus of many forging companies - but the high investment costs for tools and equipment prevents the economical benefit of the process. With flat cross wedge tools and corresponding rolling machines tooling costs can be reduced and the process is therefore interesting for small batches. Moreover, studies show that CWR is also applicable in warm temperature range.
warm forging, process chain, cross wedge rolling
In this paper the development of the new production technology hybrid forging is described. Hybrid forging combines forming of bulk and sheet metal-elements including joining. Therefore the classification of hybrid party by material and by the type of the semi-finished product is discussed. In addition, the benefits of hybrid parts are explained. In experimental forging tests with simple geometries a cylindrical bulk part was joined positively with a sheet metal by form closure. A material bond was only partially achieved.
hybrid, forging, sheet metal forming, joining technology, steel, adhesive bond
Closer tolerances, reduced surface roughness, no scale and reduced decarburization can be realized by warm forging. However, the geometrical spectrum of warm forged parts is limited by flow stress. To overcome this geometrical limitation, innovative warm cross wedge rolling and forging processes are developed in the project presented in this paper. To investigate the effect of lower temperatures on process parameters, e. g. force, die wear and material properties in comparison to hot forming processes, Finite Element Analysis (FEA) and experimental tests using downsized model geometry were performed. In this paper the new warm cross wedge rolling process is explained and results of warm cross wedge rolling trials (e. g. work piece characteristics), FEA simulations of forming forces and material analysis are shown. The results of these analyses allow industrial application of warm cross wedge rolling for the first time.
warm forging, process chain, cross wedge rolling
Many forged parts include piercings e.g. as bearings. The web of the forged pieces has to be pierced in an additional manufacturing step. By integrating this so far separately performed operation into the final forging step the process chain can be shortened. However, up to date there is no information available on how the process parameters influence quality relevant factors. Therefore, a combined forging-/piercing process is designed and performed. The results of previous research projects showed that the variation of the inserted mass and the forging temperature have a distinct effect on the dimensional and form accuracy of the work pieces. In this project different punch and work piece geometries and the influence of a different forming sequence on tool stress and the material flow was investigated. The punch and work piece geometry show no effect on form accuracy of the piercing while an inappropriate forming sequence leads to failure of the tool.
forging, flashless, precision, piercing
Economic efficiency and quality are both deciding competitive factors for companies with a production of industrial goods. To produce and deliver parts of a steady high-quality and simultaneously at low costs is a big challenge. An example is the industrial sector of injection moulding. A new software provides help by constructing canals closer to the surface. Therefore the quality of the parts increases and the cycle time decreases. Beyond this the effort for the constructor is optimized.
injection moulding, temperature mangement, software deveopment
A new tool design and die assembly developed at IPH has the ability to form flashless, near-net-shape forgings and pierce the workpiece all in one stroke. The tooling concept for the combined flashless forming and punching process was developed for rotationally symmetric parts. The die assembly is designed to fit into a standard forging press. The tool consists of an upper die, an upper punch (combined forming and punching die), gas-filled springs, a lower die, a lower punch and a release mechanism. The design of this forging sequence was facilitated by material-flow simulation programs using finite element analysis (FEA) techniques.To determine the influencing parameters forging trials have been made on Muller Weingarten PSH 265 screw press. The feasibility of a combined forming and punching process to produce near-net-shaped parts has been successfully demonstrated.
forging, flashless, precision, piercing
Aluminum Metal Matric composites show a high strength/density ratio. These materials can combine the advantages of aluminum and ceramic. A research project at IPH investigated the precision forging of Aluminum MMC to establish forging processes for Aluminum MMC and to allow a high batch production.
aluminium metal matrix composites, FEA, flashless forging
Diamond-like carbon coatings (DLC coatings) are anti-adhesive and extremely hard (up to 3500 HV) therefore they are outstandingly suitable as a wear-resistant coating. This ability to reduce tool wear in the warm forging is investigated by simulation and experimentally in IPH.
dlc, coating, warm forging
Saving resources becomes more and more important. Therefore the forging industry tries to develop processes with less flash than the conventional techniques or to avoid flash completely. Currently only simple parts like gears can be forged without flash. In a research project flashless forging processes for crankshafts were developed. In this paper the evolution of the flashless forging process and the process steps will be described. The collaboration research project "process chain for the production of precision forged high performance parts" has been conducted in the last few years at IPH and was funded by the German Research Foundation (DFG).
precision forging, flashless, crankshaft
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, the challenges regarding 8D report-based complaint management were presented as a major focus of current research.
quality management, complaint management, 8d report, data mining, text mining
For systematic processing of complaints the German Association of the Automotive Industry (VDA) recommends the 8D-method. However the method is commonly used in different industrial sectors, the lack of adequate means to assess complaint quality hinders correct and efficient complaint processing. The article presents the development of a set of indicators that addresses the above described problem. Implemented in a software prototype the indicators are determined in part by text mining algorithms as well as manually, e.g. by complaint process managers. Future research work will address the validation of the indicator set and its applicability in industry.
quality management, complaint management, 8d report, data mining, text mining
Manufacturing companies are now more than ever surrounded by a turbulent market environment. At the same time, the importance of networks and value-added networks. In theory and practice over and above the classical flexibility beyond mutability is seen as a precondition to be able to survive in this environment. Unfortunately, many companies are contrary to a number of technological and organizational change barriers in achieving versatile factory and network structures. This article gives an overview of the state of research and the development needs of the mutability of supply chains. In addition, requirements and potential solutions are presented, by what technologies and methods in the future the versatility can be improved and conversion barriers can be dismantled. The conversion-design of transport, storage and IT systems as well as planning and evaluation of the adaptability in supply chains are described mainly.
mutability, supply, factory and network structures, technological and organizational change barriers
Flashless precision forging is a special process of drop forging performed in closed dies. This process is distinguished by high quality and the ability to achieve a near net-shape part. Latest research results have shown that it is possible to forge a two-cylinder crankshaft without flash. This was realized using a multi-directional forging tool and a flashless precision forging operation. In this paper a new method for a three dimensional shrinking compensation is presented that facilitates the construction process
forging flashless precision near-netshape
Due to converting material flow in assembly areas inadequacies in logistics often lead to disturbances, bottlenecks and adaptation costs. In this contribution an approach is introduced, which systematizes the time-dynamic description of all processes for the assembly regarding relevant logistic and monetary targets. In this way it contributes to a comprehensive process and system understanding.
production planning and -steering, assembly throughput diagram, assembly controlling
The paper presents a method based on a semantic similarity search that supports employees in diagnosis and finding solutions. This semantic search methods have been modified and applied to find thematically similar service cases even when no identical symptoms are described. Using the method information about the machine, the customers and the service cases can be documented and made available to employees involved in the service process. The method was implemented in a software demonstrator.
semantic search, similarity search, service
