Project in the Field of Research
Numerical Modeling and Process Design
Energy-efficient warm solid forward extrusion (DuPressKo)
In demanding cold solid forward extrusion processes, where higher-strength materials are formed to complex component geometries, formability of the workpiece is likely to be exceeded. As a consequence, inner cracks arise. They are called chevron cracks and make components unusable. It is industrial praxis to apply warm forming in order to increase workpiece material formability. Here, the wrought material is heated homogeneously prior to forming. This is inefficient since workpiece areas, that are not susceptible to cracking, are heated as well. The hybridization of solid forward extrusion based on the integration of electrical resistance heating makes a local heating of the chevron crack-susceptible area possible. This can be used for an energy-efficient process design.
In collaboration with Schondelmaier GmbH Presswerk - a manufacturer of bulk metal formed components - a hybridized forming process for energy- and resource-efficient manufacture of warm solid forward extruded parts was developed. The project was funded by the Federal Ministry for Economic Affairs and Energy (BMWi) within a ZIM (Zentrales Innovationsprogramm Mittelstand) initative. The developed process uses an electrical resistance heating in the forming tool. The process was developed under laboratory conditions and finally tested under industrial conditions.
Based on the gained insigths design guidelines were derived and process boundaries regarding key figures for energy-efficiency were determined. The results were published and presented at the German Cold Forging Group (GCFG).
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