Forming technology: From the induction system to the cross wedge rolling machine

Tool lengths of up to 1500 mm and widths of up to 280 mm can be realized on the IPH cross wedge rolling machine in flat-jaw design. The feed forces are provided by hydraulic aggrates and amount to 125 kN. This means that workpiece diameters of up to 50 mm can theoretically be rolled.

A special feature of our cross wedge rolling machine is the possibility of process monitoring during the rolling process by means of temperature and pressure sensors. Thin-film sensors from the Fraunhofer Institute for Surface Engineering and Thin Films IST allow direct temperature measurement (up to 600 °C) on the surface of the rolled parts with very low latencies.

We are happy to carry out rolling tests according to your specifications.

The highly flexible high-tech induction heating system from EMA-TEC GmbH enables us to heat a wide variety of geometries in small quantities with little set-up effort.

The wide frequency range from 1 kHz to 10 kHz allows the voltages to be adjusted and enables the temperature curve for different materials to be controlled in a targeted manner. This allows us to heat components with an inhomogeneous temperature profile or hybrid components made of different materials in a customized manner. The short heating times result in minimal scaling.

The modular design of the system allows easy conversion of the inductors.

We use the Cobot UR 5e from Universal Robots in research projects in the field of process technology. It is used to automate process routes and work steps - for example, the handling of forged parts after induction heating. The cobot removes the heated semi-finished products from the induction system and places them in the forming press.

We use our NEFF DZP 630 double-column deep-drawing press to investigate innovative tool concepts and complex material flows. The main areas of application for the press are cross wedge rolling with flat jaws and multidirectional forging.

The press has a ram force of 6300 kN and a maximum ram stroke of 800 mm at a maximum forming speed of 400 mm/s. The press table is 1300 x 1080 mm² in size.

We use our Weingarten PSH 4.265f direct-drive screw press with a pressing force of 11000 kN to test the forming capacity of forged parts and for wear tests on the forging dies.

The main areas of application of the press are burr-free precision forging, burr-reduced forging, warm forging and hybrid forging. The press table measures 530 x 700 mm² and the maximum ram stroke is 450 mm with a maximum ram speed of 670 mm/s. An IoT gateway, which sends the machine data directly to a cloud-based database, allows us to evaluate our forming tests quickly and based on data.