The Institut für Integrierte Produktion Hannover (IPH) has developed a new forging procedure which considerably saves material and energy. In the EU project REForCh, researchers were able to reduce the burr percentage in the forging of crankshafts from 54 to 7 percent and were moreover able to save approximately 20 percent on energy. The procedure has already been successfully tested in the industrial environment. It is only a small step to the application stage.
For two years, the IPH researched the procedure – with funding from the European Union and in close collaboration with companies from Spain, Romania and Turkey. The result: The researchers were able to significantly reduce the burr percentage in the forging of a two cylinder crankshaft.
Significantly lower burr percentage: The multi-directionally forged crankshaft (right) compared with a conventionally forged one. (Graphics: IPH)
In conventional forging procedures, 10.8 kilograms of steel had to be used to forge the 7 kilogram-heavy crankshaft – that corresponds to a burr percentage of 54 percent. With the new, multi-directional forging procedure, the burr percentage decreases to only 7 percent: In order to produce this same crankshaft, 7.5 kilograms of steel suffice. Moreover the new procedure saves about 20 percent energy because less steel must be heated.
The savings are possible through so-called multi-directional forging. In conventional forging procedures, metal forming is done exclusively through pressure from above. Surplus material escapes to the sides. This results in the forming of the so-called burr that must subsequently be removed. Using multi-directional forging, the heated steel is reformed not only from above but also by simultaneous pressure to the sides. Thus the steel can be pressed in form in a more controlled manner and less material is wasted.
The IPH has already been working on the multi-directional forging for more than ten years and has developed it further in several research projects. As part of the EU project REForCh, the procedure has now been successfully tested for the first time in the industrial environment. REForCh stands for "Resource efficient forging process chain for complicated high duty parts".
Approximately 1.1 million euros have been invested in the research project by the EU. A total of six companies and research institutes from Germany, Spain, Romania and Turkey were involved in the project. The Institut für Elektroprozesstechnik (ETP) of the Leibniz University of Hanover designed the induction heating processes and studied the energy balance of the forging procedure. The Spanish company Aurrenak produced the forming tool which can be inserted into a perfectly normal eccentric press and diverts the press pressure so that the steel is formed simultaneously from above and from the sides.
The new procedure was successfully tested in Turkey: The forging company Omtaş Otomotiv Transmisyon Aksami has ready produced prototypes of two cylinder crankshafts for quads and snow mobiles using the multi-directional tool and would like to now transfer the procedure to the production of other crankshaft types. It is only a small step to application stage.
The research results benefit all forging companies who want to save on materials and energy: The Institut für Integrierte Produktion Hannover (IPH) will be happy to forward the findings obtained from the project and advises companies on the multi-directional forging method. Contact is Dr. Malte Stonis, who can be reached at the phone number +49 (0) 511 279 76-336 or via e-mail at firstname.lastname@example.org.
Susann Reichert | idw - Informationsdienst Wissenschaft
More functionalities: Microstructuring large surfaces with a UV-laser system
05.07.2018 | Fraunhofer-Institut für Lasertechnik ILT
A factory to go
04.07.2018 | Fraunhofer Institute for Manufacturing Engineering and Automation IPA
For the first time ever, scientists have determined the cosmic origin of highest-energy neutrinos. A research group led by IceCube scientist Elisa Resconi, spokesperson of the Collaborative Research Center SFB1258 at the Technical University of Munich (TUM), provides an important piece of evidence that the particles detected by the IceCube neutrino telescope at the South Pole originate from a galaxy four billion light-years away from Earth.
To rule out other origins with certainty, the team led by neutrino physicist Elisa Resconi from the Technical University of Munich and multi-wavelength...
For the first time a team of researchers have discovered two different phases of magnetic skyrmions in a single material. Physicists of the Technical Universities of Munich and Dresden and the University of Cologne can now better study and understand the properties of these magnetic structures, which are important for both basic research and applications.
Whirlpools are an everyday experience in a bath tub: When the water is drained a circular vortex is formed. Typically, such whirls are rather stable. Similar...
Physicists working with Roland Wester at the University of Innsbruck have investigated if and how chemical reactions can be influenced by targeted vibrational excitation of the reactants. They were able to demonstrate that excitation with a laser beam does not affect the efficiency of a chemical exchange reaction and that the excited molecular group acts only as a spectator in the reaction.
A frequently used reaction in organic chemistry is nucleophilic substitution. It plays, for example, an important role in in the synthesis of new chemical...
Optical spectroscopy allows investigating the energy structure and dynamic properties of complex quantum systems. Researchers from the University of Würzburg present two new approaches of coherent two-dimensional spectroscopy.
"Put an excitation into the system and observe how it evolves." According to physicist Professor Tobias Brixner, this is the credo of optical spectroscopy....
Ultra-short, high-intensity X-ray flashes open the door to the foundations of chemical reactions. Free-electron lasers generate these kinds of pulses, but there is a catch: the pulses vary in duration and energy. An international research team has now presented a solution: Using a ring of 16 detectors and a circularly polarized laser beam, they can determine both factors with attosecond accuracy.
Free-electron lasers (FELs) generate extremely short and intense X-ray flashes. Researchers can use these flashes to resolve structures with diameters on the...
13.07.2018 | Event News
12.07.2018 | Event News
03.07.2018 | Event News
16.07.2018 | Physics and Astronomy
16.07.2018 | Life Sciences
16.07.2018 | Earth Sciences