On the one hand the precision forging involves substantial savings in material and process heat as well as in the reduction of the process steps. On the other hand, the tools are also much more exposed than the conventional forging. This leads to more rapid wear and a lower tool life of the tools. Within the framework of the subproject C4 of the Collaborative Research Center (SFB) 489 "process chain for the production of precision forged high performance components", therefore, a simulation-based approach will be developed, which allows the evaluation of new technical and organizational measures to improve the tool insert and thus supports a transfer into industrial practice.
precision forging, tool insert
Multi-directional forging enables flashless preforming for complex workpiece geometries by a cross-section formation and mass distribution in one forging stroke of the press. The process principle is based on a tool with multi-directional acting forming punches. In addition to the vertical forming by a punch a horizontal deformation is performed by horizontally arranged sliders. The drive of the sliders is performed by a redirection of the ram movement using wedges. The multi-directional forging has been studied and developed further over the past decade in a number of research projects. Starting with simple flashless, flat preforms for connecting rods made of steel, the technical feasibility of this method has been demonstrated. In subsequent steps, the principle has been transferred to crankshafts. As part of the Collaborative Research Centre 489, the crankshaft was broken down to a unit cell in order to investigate the fundamental transformation of the bearings and the crank webs. With this knowledge, forging sequences for simplified single and two-cylinder crankshafts were designed (without secondary form elements). Currently the forging sequence for a full two-cylinder crankshaft is designed with secondary design elements. The interaction of the mass distribution by cross-wedge rolling and multi-directional forging is analyzed. The flashless forging of two-cylinder crankshafts with such complicated geometries and corresponding necessary material flow is only possible using a multidirectional preforming. Finally, the applicability of the method to aluminum was investigated in the context of a DFG project – again based on a flat part long preforms. Here particularly clearly the limits of the process could be shown. Various forming directions were combined. With some of these combinations flash developed during the forming operation. Others have shown to be usable for a flashless preforming of complicated geometries.
multidirectional forging, flashless, preforming, cross-wedge rolling, connecting rod, crankshaft, st
8D reports often suffer from poor quality that could hinder effective troubleshooting within industrial supply and production processes. Thus, two research institutions developed a metric system that could help to detect poor quality 8D reports. Implemented in a software prototype the metric system can help to comprehensively improve complaint management processes.
quality management, complaint management, 8d report, data mining, text mining
The production machines in sheet metal forming are characterized by chaining of complex processes. Disruptions in a process can therefore shut down entire production lines and lead to high losses. Knowledge of disturbances and associated corrective actions in this case achieve a high degree of complexity, so that effective management and recording of this knowledge requires computer support.
sheet metal forming, experience recovery, equipment effectiveness
Function based structures for cost estimating. The complexity and the unique character of tool and mould constructions are the reasons why the calculation during the offer phase of the moulds and tools are using customer requirements and insufficient product information as a basis. For this purpose an increasing number of commercial software packages are used. Nevertheless, the support for the calculation is still inadequate. The IPH develops a method which allows a precise, transparent and with little effort achievable estimation for an offer on the basis of tool functions and the knowledge about already produced tools in a company.
function-based method, tender preparation, injection molding
The increasing complexity of factory planning tasks requires new methods and tools for accumulating planning stages. To make the process of factory planning for their clients more efficiently the IPH and RMA have developed in numerous successful projects and a joint as far as possible parallel action for the implementation of factory planning. Through constant exchange of information and coordination of the offices from both sides of methods and tools the efficiency of factory planning projects jointly implemented could be increased in terms of "power form". The basic idea is a parallel development of the factory of process and space perspective.
factory planning, complexity
To survive in the rivalry of competing supply chains in strong market dynamics, logistic measures of single companies are no longer sufficient. The reaction to disturbances needs to be aligned within the supply chain. Otherwise losses of efficiency result as increased inventory costs and reduced logistic performance. These losses are caused in early tiers of the supply chain. Due to the Bullwhip effect, they result in highly amplified inefficiencies throughout the complete supply chain. This article presents the development of a methodical support for synchronising the logistic reaction in supply chains. Therefore, reactions on disruptions and demand changes are determined and – according to their effect on logistic objectives – quantified. Cause-effect relationships of all processes within the supply chain (Source, Make and Deliver) are identified.
supply chain management, logistic reactivity
As a result of increasing globalization in procurement an increased competition exists for production companies. In the field of sheet metal forming companies will therefore be required to produce proper quality products with short delivery times at high punctuality at lowest possible production costs.
sheet metal forming, experience recovery, equipment effectiveness
In a current research project at IPH – Institut für Integrierte Produktion Hannover gGmbH and Laser Zentrum Hannover e. V. the knowledge of die failure mechanisms during the forming of aluminium will be extended. Aspects of the analysis are minimization, quantification and forecasting of adhesion. Furthermore it will be analysed in what way the tools, laser-dispersed with aluminium oxide, decrease the adhesion.
aluminium forging, wear, wear coatings
The German forging industry is under ever increasing pressure to develop innovative products at low prices. The design of logistic efficient forging processes regarding economic aspects is an opportunity for cost reduction. Thereby, sumultaneous consideration of technological interfaces as well as indirect processes (e.g. tool logistics) leads to a continuous process chain optimization. Logistic effects of resulting process changes have to be identified within a dynamic production controlling system in order zu improve the logistic performance.
logistical optimization, process chain optimisation, production planning and -steering
The planning and configuration of cyclically interlinked production systems, which are for example used for assembly of electric motors, is often carried out under great time pressure in the bidding phase. Data mining methods allow a high time saving approach in tender preparation. Based on this technology, the IPH developed a software to shorten the planning time and to improve the planning results.
interlinked production systems, planning, characteristic curves, data mining
This paper presents the application of radio frequency identification (RFID) as an electronic authenticity certificate for pharmaceutical packaging along the pharmaceutical supply chain. It focuses on the one hand on the assurance of the supply chain to protect against plagiarism and on the other hand on the production of an electronically secured packaging. In order to realize a secured packaging, a RFID-transponder is integrated in the folded box. The data saved on the RFID-chip is inseparably connected with the folded box.
product protection, rfid, identification technologies, folding boxes, antenna printing
This lecture presents the application of radio frequency identification (RFID) as an electronic authenticity certificate for pharmaceutical packaging along the pharmaceutical supply chain. It focuses on the one hand on the assurance of the supply chain to protect against plagiarism and on the other hand on the production of an electronically secured packaging. In order to realize a secured packaging, a RFID-transponder is integrated in the folded box. The data saved on the RFID-chip is inseparably connected with the folded box.
product protection, rfid, identification technologies, folding boxes, antenna printing
This lecture presents the IPH and introduces its topics. In particular, research projects and cooperation opportunities are addressed.
software development, production research
Increasingly, purchasing decisions for equipment are determined by the offered service and suppliers are changed in order to dissatisfaction with the service. But service quality and efficiency can already be increased in the hotline of the manufacturer. Two research institutes in Hannover are currently developing a software system based on semantic similarity search of service cases.
semantic search, similarity search, service
Most companies have different production logistic strategies. In practive, the control of them is very difficult. Therefore, a manual is developed.
production logistics, control of productions strategies, key performance indicators
For identification of requirements of tasks and objectives in the state of the art of logistic controlling of small and medium-sized companies (SMCs), the IPH have carried out a study. In this study, the results are categorized in propagation, focuses and development needs.
study, logistic-controlling, production logistics
Design and configuration of model-based rules. Disruptions in production with negative impact on the objectives of production logistics need to be identified and resolved. Small and medium sizes enterprises (SMEs) often lack of sufficient human capital to control the logistic relations in production and thus to realize a targeted improvement of a logistic process. Moreover, a profound knowledge about the complex relations between logistic objectives and measures against interferences in production is often missing. The missing knowledge of coherences may explain why aspired logistic objectives in SMEs are often not achied. This article introduces an approach for diagnosing interferences in production logistics and deriving recommendations for measures using an assistance system developed at the IPH - Institute of Integrated Production Hannover gGmbH.
assistence system, objectives of production logistics, diagnose of interruptions in production
A functional logistic strategy for production logistics may be deduced from a corporate strategy in order to ensure competitiveness. The challenge is to monitor the strategic guidelines by appropriate key data. When the monitoring identifies divergences, a diagnosis helps to derive measures at the operational level in order to ensure stable or improved processes. The paper introduces a rule-based expert system to help master these challenges. The approach is based on the production logistic objectives (low work in process level, short throughput time, high schedule reliability and high utilization) with their key indicators. In a problem solving tree, those key indicators are connected with further significant diagnostic key data, according to their cause-effect relationships. The expert system rules are based on the fundamental laws of production logistics by Wiendahl and Nyhuis. A diagnostic procedure for production logistics will be triggered by quality control charts in an expert system.
knowledge management in production and logistics, ict for manufacturing and logistics, intelligent,
During the utilization phase, sheet fabricating tools cause up to 70% of their own life cycle costs. In general, they may now be procured only on the basis of their purchase price. IPH - Institute of Integrated Production Hannover gGmbH has developed a method which can predict and consider the life cycle costs based on knowledge of these tools during the planning process.
calculation, life cycle costs, tool manufacturing
