Our comprehensive equipment is used in research projects as well as on behalf of our customers. Our services include forging tests conducted on our in-house forming machines, testing and analyses carried out with IPH measurement technology, and simulations and calculations using professional software.
The flexible induction heating system from EMA-TEC GmbH makes it possible to heat a wide variety of geometries in small quantities with little set-up effort. The modular design allows easy conversion of the inductors.
In addition, the wide frequency range from 1 kHz to 10 kHz allows the voltages to be adjusted and allows the temperature curve for different materials to be specifically controlled.
On our double column deep drawing press NEFF DZP 630 we investigate innovative tool concepts and complex material flows. The main areas of the press are cross-wedge rolling with flat tools, hydroforming and multi-directional forging. The maximum force of the press is 6300 kN. The maximum ram stroke is 800 mm while a ram speed of 400 mm/s can be reached. The press table is 1300 x 1080 mm² in size.
Cross-wedge rolling apparatus
The cross-wedge rolling apparatus of IPH is constructed in flat wedge design. It has a tool length up to 1500 mm and a width up to 280 mm. The forming forces are realized by hydraulic power units. The maximum force is 125 kN and thus theoretically workpiece diameters up to 50 mm can be rolled. We offer to perform rolling tests according to your specifications. You also can buy the cross-wedge rolling apparatus. We offer it in two versions: as a module, for use in a hydraulic press, and as a standalone device. The sizes of the tool systems are variably.
Our directly driven screw press Weingarten PSH 4.265f has a press force of 11000 kN. We use it for investigating the formability of forging parts and for wear analysis of forging dies. The main areas are the flashless precision forging, flash reduced forging, warm forging and the new hybrid forging. The press table is 530 x 700 mm² in size and the maximum ram stroke is 450 mm at a maximum ram speed of 670 mm/s.
The LZ 400VS-G precision center lathe is a compact, precise universal center lathe with toolmaker's accuracy. We use it to machine forging and rolling samples. We can also use it to produce or rework small tool parts for our forging and rolling tools. We also produce or rework parts for machine stops or ejectors on the lathe.
Research area: Additive plastics recycling
The research area for additive plastics recycling was opened in 2020 and has two research rooms. In the front room, several computer workstations and a 3D profilometer are available for use. The printer room, separated by a soundproofed glass wall, offers several additive manufacturing systems, a complete recycling chain for thermoplastics and testing technology for research and customer orders. A state-of-the-art ventilation system with up to 8-fold air exchange is also installed.
Optical 3D measuring system
For the 3D measuring of small to medium-sized components such as forgings, at IPH we use the optical 3D scanner ATOS Core developed by GOM. The system can be used with the sensor Atos Core 500 to measure objects up to 500 x 380 mm with an accuracy of 65 micrometers. The sensor Atos Core 80 (see figure) is suitable for objects smaller than 80 x 60 mm, these can be measured with an accuracy of up to 15 micrometers.
Test rig for conveyor belt idlers
We offer independent testing services for manufacturers and users of conveyor belt idlers. The running characteristics of conveyor belt idlers are tested in accordance with testing standards DIN 22112, SAB 1313 and DIN ISO 21940. For this purpose we dispose of measurement technology and modern test rigs.
We can test conveyor belt idlers with a maximum diameter of 400 mm and a length of axis of up to 1650 mm.
The electronics laboratory has two places for soldering as well as a device for the making of electric prototypes. In addition to laboratory power supplies and frequency generators for signal generation, the IPH has an analog and a digital oscilloscope for signal analysis. In addition, instruments for luminescence or spectral measurements are available.
In the creative room, our employees and project partners can come up with new ideas away from the desk. The equipment encourages reflection and creativity.
Up to seven people can write, scribble or draw on the IdeaWall at the same time - the results can then be stored digitally. The Pixel wood blocks can be put together at any time to different furniture such as tables, stools or benches. The comfortable, colorful sofa as well as armchairs and whiteboards complete the space.
Software for material flow simulation
For the implementation of discrete event material flow simulations, we use the software Plant Simulation. With the software Sim 3D we create animations and simulations of production and logistics systems. Movements and material flows are simulated realistically, taking account of physical properties such as gravity, friction and inertia.
The use of material flow simulations offers great advantages in new and re-planning of production, warehousing and logistics systems and increases planning reliability.
Computing and visualization software
To carry out complex numerical calculations and modeling of technical systems, we have the software MATLAB/Simulink available, including relevant toolboxes.
In order to visualize measurement data and create user interfaces for machines or test rigs we use the software LabVIEW.
In our research projects we usually use the CAD program Creo Parametric. With it, we construct forming tools for flashless precision forging, multi-directional forging, cross-wedge rolling and hydroforming.
In addition, we use the CAD program SOLIDWORKS Simulation. After the construction we simulate for example the tool deformation under load. This is particularly useful for complex tooling systems like the flashless precision forging and multi-directional forging.
For the simulation of forming processes we use the finite element method (FEM). The material flow of forging, cross-wedge- and ring-rolling processes is simulated with the software Forge NxT. Using LS-DYNA we simulate hydroforming processes. The innovative hybrid forging as well as the reduction of die wear during drop forging are simulated with Simufact. The software AnsysMechanical is used to calculate thermal and mechanical loads of our forming tools.