Flashless precision forging is a high quality process which is used to produce near net shape forgings in the tolerance class from IT 8 to IT 10. Representative parts produced by this process are gear-wheels or joint heads. Many forged parts have drillings e.g. as bearing surfaces. These parts are produced in two separate processes: forging and the through hole piercing process. Scope of a research project of the IPH - Institute of Integrated Production Hannover is to realize the combination of the two processes into one flashless precision forging process. Example parts are a rotation-symmetric part similar to gear-wheels and a part with a distinct longitudinal axis which is similar to joint heads. For both parts the forging process was simulated and forged on a screw press. It was shown that a combined forging/piercing process is feasible. Further investigations of the microstructure and the quality of the drilling surfaces of both parts are planned for comparison.
flashless precision forging, punching, tool design
Resources and cost efficiency as well as process optimisation are key factors in today’s market. The competition pressure in forging industry is increasing steadily. Today, parts with openings, cut outs or something similar are punched and partially deburred in hot state after the actual forging process. The combination of forging and punching in one process offers the opportunity to save money and time.
flashless precision forging, punching, tool design
Many forged parts have drillings e.g. as bearing surfaces. These parts are produced in two separate processes: forging and the through hole piercing process. Scope of a research project of the IPH - Institute of Integrated Production Hannover is to realize the combination of the two processes into one flashless precision forging process. This combination lowers the process time, the amount of raw material and the number of tools and faults. Example parts are a rotation-symmetric part similar to gear-wheels and a part with a distinct longitudinal axis which is similar to joint heads. For both parts the forging process was simulated and forged on a screw press. It was shown that a combined forging/piercing process is feasible. Further investigations of the microstructure and the quality of the drilling surfaces of both parts are planned for comparison
flashless precision forging, punching, tool design
Efficiency, reducing costs and optimization are important factors for companys. Achieving this means to reduce the amount of raw material, production time and production steps. IPH – Institut für integrierte Produktion Hannover has developed a combined process for piecing and flashless forging that shortens the number of steps within the process. This new operation is suitable for rotation-symmetric parts as well as for elongated parts. Combing forging and piercing leads to less requirement of raw material and a shortend process time. This was successfully testesd at IPH.
flashless precision forging, punching, tool design
The cross linking of companies on turbulent Markets cause an increasing dynamic in individualized productions and places high requirements on software applications which are used within companies. The availability of necessary data across company borders within production networks through an interlinking of applications is only one challenge, applications are facing in order to achieve a high level of process transparency.
mes, erp, shop floor, process transparency, supply chain
Warm forged parts are distinguished by good surface properties and high dimensional accuracy. In comparison to hot forging the maindisadvantage is the high wear of the forging dies because of the higher mechanical load. Diamond-Like Carbon (DLC) coatings are anti-adhesive and extremely hard (up to 3500 HV) and are thus suitable as wear protection coatings. The suitability of these kind of coating is examined by simulation and experiments at the IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH. For this purpose, a modular test rig was developed, which enables the detection of relevant process parameters, e.g. as the die temperature. The project aims at a reduction of die wear and a wa to demonstrate the wear process, depending on the process parameters.
DLC, coating, warm forging
For the forging process, semi-finished steel products are predominantly manufactured by shearing bar stock. However, the geometry and volume accuracy of sheared sections of bar stock, due to shearing errors, is inadequate for some forming processes, in particular for precision forging. Hence, it is necessary to optimize the shearing process. By an oscillating movement of the shearing blade, the shearing surface quality can be improved, thereby increasing the accuracy of the geometry and the volume.
billet shear, forging, swinging
Quality requirments are demanding wear protection for forging dies to ensure a long life time in combination with dimensional accuracy. This paper describes the investigation of yet unknown coatings in the forging industry like laser based hard coatings and diamond like carbon coatings.
aluminium forging, wear, wear coatings
The complaint processing in the customer-supplier relationship is costly and time consuming and often incorrect. At the Institute of Metal Forming and Metal Forming Machine Tool (IFUM) will together with the IPH - Institute of Integrated Production Hannover gGmbH developed a measurement and evaluation system to improve the quality and reduce costs in the processing of complaints involving the 8D method.
processing of complaints, method of valuation, cost reduction, 8d report
The processing of complaints involving the 8D method is sometimes very costly and time consuming and often error-prone. Against this background, an automated metric system for measuring and evaluating the quality of processing of an 8D report is presented in the article. On the one hand text mining algorithms are used to determine the metrics. On the other hand manual reviews are used to realize the required bandwidth at reviews efficiently and reliably. The metric system was implemented in software and is designed to enable companies in various industries to reduce the expense of an effective fault management significantly, to shorten response times in the event of a complaint and to benefit from a long-term avoidance of errors.
quality management, complaint management, 8d report, data mining, text mining
For more than 22 years, IPH has been researching and developing in the field of production technology. What are the company's plans for the future?
This article describes the logistic challenges of producing in networks. Followed by a definition of a production network, the greatest chances as well as the potential risks of producing in networks are identified. The unique features and requirements of network production in comparison with single enterprise production are pointed out and the production logistic research need is derived.
production, production networks, logistics, xxl-products
Short-term, considerable need rises in the production require short-term capacity rises by capacity flexibility which is connected with a reaction time. In the context of a project sponsored by the German research council a possibility has been developed to bridge the reaction time by a short-term, article general reduction of outputs.
ability to deliver, lot size, production planning and control, capacity flexibility
In comparison with the conventional forging with flash, precision forging helps to reduce the amount of raw material. Beyond this no additional step for flash removal is needed. In this paper the development of a three step process for a two cylinder crankshaft with flange and pin is described and afterwards compared to a four step process. It shows that the three step process lowers the number of faults saves time and forces. These advantages are due to the innovative tool concept which is shown in this paper.
cross wedge rolling, bi-directional forging, crankshaft forging without flash
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
