| Theme | Forming technology, Tool- and Mold-Making |
|---|---|
| Project title | Burr avoidance in flash-free forging of aluminum under consideration of industry-related process parameters and variation of tool-integrated sealing concepts (FlidiAl) |
| Project duration | 01.11.2020 – 31.10.2022 |
| Press release |
The use of flash-free forging in the aluminium forging industry is significantly complicated by the formation of burr, which limits the advantages on the process side and extends the process chain through machining finishing.
The research objective is to avoid the burr by tool-integrated sealing concepts and to predict the formation of burr taking into account industry-related process parameters in the flash-less forging of aluminium. In cooperation with Otto Fuchs KG, a systematic investigation of the process conditions in an examination tool with four universally valid burr cases will be carried out and subsequently a sealing concept will be developed. For this purpose, the influence of the sealing concepts on the sealing effect is identified in experimental investigations consisting of functionality and wear investigations.
Based on the findings, an extended forecast model for burr can be developed.
Publications about the project
A major advantage of flashless precision forging is the saving of resources by avoiding excess material. Especially materials with good flow properties, such as aluminum, sometimes lead to the formation of thin flash. Seals have been developed and experimentally tested to prevent thin flash, i.e. the flow of material into tool gaps. The study presented shows the effectiveness of different sealing materials and the ideal sealing geometry.
thin flash, Sealing concept, precision forging, forming technology, process optimization
Process Optimization through Thin Flash Prevention. Due to the good flow properties of aluminum, the material tends to flow into tool gaps during flashless precision forging and produce the so-called thin flash. For the industrial implementation of flashless precision forging processes, an innovative prediction method for thin flash as well as sealing concepts are to be developed in cooperation with an industrial partner. Simulative studies show that local form filling does not correlate with high pressure or an increased potential for thin flash.
thin flash, FEM-simulation, sealing concepts, precision forging, forming technology
In cooperation with Otto Fuchs KG, IPH is researching methods to predict and avoid thin flash during flashless forging of aluminum. The development of target-oriented sealing concepts should significantly increase process efficiency in the future.
flashless forging, aluminum, thin flash, sealing concept
