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.
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.
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.
An 'octopus' robot with eight limbs developed to clear rubble in Fukushima, Japan
23.03.2015 | Waseda University
An Apparatus For Dispensing A Rolled Material
23.03.2015 | Universiti Teknologi MARA (UiTM)
In an experiment at the Department of Energy's SLAC National Accelerator Laboratory, scientists precisely measured the temperature and structure of aluminum as...
The IPH presents a solution at HANNOVER MESSE 2015 to make ship traffic more reliable while decreasing the maintenance costs at the same time. In cooperation with project partners, the research institute from Hannover, Germany, has developed a sensor system which continuously monitors the condition of the marine gearbox, thus preventing breakdowns. Special feature: the monitoring system works wirelessly and energy-autonomously. The required electrical power is generated where it is needed – directly at the sensor.
As well as cars need to be certified regularly (in Germany by the TÜV – Technical Inspection Association), ships need to be inspected – if the powertrain stops...
When an earthquake hits, the faster first responders can get to an impacted area, the more likely infrastructure--and lives--can be saved.
The Atlantic overturning is one of Earth’s most important heat transport systems, pumping warm water northwards and cold water southwards. Also known as the Gulf Stream system, it is responsible for the mild climate in northwestern Europe.
Scientists now found evidence for a slowdown of the overturning – multiple lines of observation suggest that in recent decades, the current system has been...
Because they are regularly subjected to heavy vehicle traffic, emissions, moisture and salt, above- and underground parking garages, as well as bridges, frequently experience large areas of corrosion. Most inspection systems to date have only been capable of inspecting smaller surface areas.
From April 13 to April 17 at the Hannover Messe (hall 2, exhibit booth C16), engineers from the Fraunhofer Institute for Nondestructive Testing IZFP will be...
25.03.2015 | Event News
19.03.2015 | Event News
17.03.2015 | Event News
31.03.2015 | Earth Sciences
31.03.2015 | Earth Sciences
31.03.2015 | Life Sciences