Increasing the service life and process reliability of systems plays an important role in terms of sustainable and economical production. Especially in the field of energy-intensive bulk forming, low scrap rates and long tool lifetimes are business critical. This article describes a modular method for AI-supported process monitoring during hot forming within a screw press. With this method, the following deviations can be detected in an integrated process: the height of the semi-finished product, the positions of the die and the position of the semi-finished product. The method was developed using the CRISP-DM standard. A modular sensor concept was developed that can be used for different screw presses and dies. Subsequently a hot forming-optimized test plan was developed to examine individual and overlapping process deviations. By applying various methods of artificial intelligence, a method for process-integrated detection of process deviations was developed. The results of the investigation show the potential of the developed method and offer starting points for the investigation of further process parameters.
Process monitoring, Wear, Hot forming, Predictive maintenance, Quality management
In the research project “AutoPress”, the IPH – Institut für Integrierte Produktion Hannover gGmbH and Jobotec GmbH are jointly striving to develop an automated process control of screw presses. By retrofitting and applying an optimization algorithm, the energy demand is to be reduced and the component quality increased.
digitalization, forming technology, production technology
The use of a digital tool for workplace evaluation makes it possible to document and evaluate production workplaces in terms of their ergonomics with little effort. As part of the digitization project, a concept for optimizing workplace ergonomics was developed with the help of a digital tool and converted into a catalog of measures. The Institut für Integrierte Produktion Hannover (IPH), as a partner of the Mittelstand-Digital Zentrum Hannover, has supported WISTRO Elektro-Mechanik GmbH from Langenhagen in a project to carry out a systematic workplace assessment within a digital tool. In addition, ergonomic optimization measures for an assembly workplace were identified and evaluated using an individual utility value analysis.
By carrying out the project, it was possible to create awareness and concrete measures for the topic of ergonomics and thus to increase the possibilities for an increase in the number of employees and thus the possibilities for increasing employee motivation.
ergonomics, digitalization, employee satisfaction
An elementary factor for influencing the process quality and the energy requirement of an energy-bound forming machine is the stored work capacity. At present, the forming energy is calculated via the work energy introduced into the system. Here, factors such as spindle torsion or frictional resistance are only taken into account roughly.
Within the framework of the research project "Development of a retrofit system for friction screw presses for automation and minimization of the set-up time and development of a sensor array for the first-time recording of elementary process variables such as the forming force" (AutoPress), which is funded by the Industrielle Gemeinschaftsforschung (IGF), the IPH - Institut für Integrierte Produktion Hannover gGmbH and JOBOTEC GmbH are striving for an automated process control of screw presses and are providing initial findings in this regard.
retrofit, forging technology, digitization
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
Student job, Master thesis, Bachelor thesis, Project thesis
