Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

IPH makes forging more efficient – on behalf of the EU

19.02.2014
A faster, cheaper and more efficient producing of titanium-parts is the aim of a new research project funded by the European Union.

The german-based “Institut für Integrierte Produktion Hannover” (IPH) is working on the project together with two other research institutes and four enterprises from five European countries.


Forged preforms created by using cross wedge rolling must be further processed in order to obtain the final shape.

Source: IPH


Cross wedge rolling in action at IPH: As part of the research project „CoVaForm“ a similar machine will be constructed and built, especially designed for titanium hip implants.

Source: IPH

Whether producing engine parts, turbine blades or hip implants: Regarding forged parts, the material is the main component of the production costs, especially if a high duty material like titanium is used. During a new research project, IPH aims to develop a process in which less material is needed and which, at the same time, decreases time and energy consumption. This way, the researchers try to reduce the overall production costs significantly. Especially small and middle-sized forging enterprises will benefit from the results.

Die forging is forming of hot metal. To produce complex high duty parts, a single forging step is not enough to realize the complex shape. Therefore, so called preforms are produced during the forging process. To produce these preforms, different techniques are used. In most of the processes a lot of material gets lost: e. g. during machining a lot of excessive material is gradually removed – just like a sculptor removes excessive stone to expose the sculpture.

Cross wedge rolling (CWR) is the most efficient way to produce preforms. In this process the hot metal is formed into shape while rolling – just like a pottery maker is forming the figures by spinning the clay and forming it through gentle pressure.

The material utilization in cross wedge rolling is up to 100 percent. Also, less time and energy is needed, compared to machining. A lack of knowledge about the design of a cross wedge rolling process in general and especially for titanium and stainless steel is a main problem for the European forging industry. But particularly for these expensive materials an efficient material utilization has a great benefit.

To examine the cross wedge rolling technology, a titanium hip implant will be forged in the research project “CoVaForm”. The IPH has gained a lot of experience in cross wedge rolling during several research projects and will now build up a new CWR machine to produce preforms for a hip implant. This CWR machine will be tested at a collaboration partner by the middle of next year.

Funded by the EU, “CoVaForm” started January 1st 2014 and will last for a period of two years. The shortcut stands for “Conservation of valuable materials by a highly efficient forming system”. The project consortium consists of four enterprises and three research institutes from Germany, Spain, Italy, Austria and Turkey. This project is financially supported by the European Union as part of the seventh framework program (RP7).

The main interest lays in the help of small and middle-sized European forging plants to remain competitive in the international market and therefore help to secure approximately 68000 jobs – the number of people working in European forging plants in 2011. The overall sale in the sector was 12 billion Euros.

Companies who use forged parts for production will benefit in the long run due to more efficient forging processes and lower costs – first of all in the automotive industry, but also in the medical- and aerospace industries.

Susann Reichert | idw
Further information:
http://www.covaform.eu
http://cordis.europa.eu/fp7

More articles from Machine Engineering:

nachricht Connecting industrial outstations inexpensively and securely
14.07.2015 | Siemens AG

nachricht Management platform enables secure and simple remote access
29.06.2015 | Siemens AG

All articles from Machine Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: On the crest of the wave: Electronics on a time scale shorter than a cycle of light

Physicists from Regensburg and Marburg, Germany have succeeded in taking a slow-motion movie of speeding electrons in a solid driven by a strong light wave. In the process, they have unraveled a novel quantum phenomenon, which will be reported in the forthcoming edition of Nature.

The advent of ever faster electronics featuring clock rates up to the multiple-gigahertz range has revolutionized our day-to-day life. Researchers and...

Im Focus: Superfast fluorescence sets new speed record

Plasmonic device has speed and efficiency to serve optical computers

Researchers have developed an ultrafast light-emitting device that can flip on and off 90 billion times a second and could form the basis of optical computing.

Im Focus: Unlocking the rice immune system

Joint BioEnergy Institute study identifies bacterial protein that is key to protecting rice against bacterial blight

A bacterial signal that when recognized by rice plants enables the plants to resist a devastating blight disease has been identified by a multi-national team...

Im Focus: Smarter window materials can control light and energy

Researchers in the Cockrell School of Engineering at The University of Texas at Austin are one step closer to delivering smart windows with a new level of energy efficiency, engineering materials that allow windows to reveal light without transferring heat and, conversely, to block light while allowing heat transmission, as described in two new research papers.

By allowing indoor occupants to more precisely control the energy and sunlight passing through a window, the new materials could significantly reduce costs for...

Im Focus: Simulations lead to design of near-frictionless material

Argonne scientists used Mira to identify and improve a new mechanism for eliminating friction, which fed into the development of a hybrid material that exhibited superlubricity at the macroscale for the first time. Argonne Leadership Computing Facility (ALCF) researchers helped enable the groundbreaking simulations by overcoming a performance bottleneck that doubled the speed of the team's code.

While reviewing the simulation results of a promising new lubricant material, Argonne researcher Sanket Deshmukh stumbled upon a phenomenon that had never been...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

3rd Euro Bio-inspired - International Conference and Exhibition on Bio-inspired Materials

23.07.2015 | Event News

Clash of Realities – International Conference on the Art, Technology and Theory of Digital Games

10.07.2015 | Event News

World Conference on Regenerative Medicine in Leipzig: Last chance to submit abstracts until 2 July

25.06.2015 | Event News

 
Latest News

Surprising similarity in fly and mouse motion vision

30.07.2015 | Life Sciences

Efficient Infrared Heat Saves Time and Energy in the Manufacture of Motor Vehicle Carpets

30.07.2015 | Trade Fair News

Roentgen prize goes to Dr Eleftherios Goulielmakis

30.07.2015 | Awards Funding

VideoLinks
B2B-VideoLinks
More VideoLinks >>>