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TOOL DESIGN METHODOLOGY FOR PRECISION FORGING OF ROTATIONAL PARTS

Objective

Precision forging represents a new technology with high economic potential. Precision forged parts are ready-to-install, their manufacture requires considerably less raw material than other production methods and their mechanical characteristics are favourable.

Currently the method to design precision forged tools is based on the "trial and error" procedure which leads to high costs in tool development.

The aim of this project is to eliminate the"trial and error" procedure and develop computer based tool design methods.
The aim of this research is to eliminate the trial and error procedure and develop computer based tool design methods for precision forging.

For the design of preform stages, case studies have been carried out to predict forging loads and metal flow in axisymmetric forging;
programmes have been developed in order to apply some design principles to the layout of rotating precision forged parts. 3-dimensional computer aided design (CAD) system EUKLID is used for this task;
3-dimensional finite element calculations for the simulation of the manufacturing sequences for bevel gears with remeshing have been carried out. The findings have been experimentally verified.

The results are ready to be transferred to industry, with great technological and commercial advantages.
Additional application packages are developed to support tool design taking into account forming forces, contact stresses, thermally activated effects, workpiece geometry and metal-forming machine tool characteristics.

Existing calculation programmes are integrated into the programme development. Stage sequences are determined under economical aspects to permit the lowest possible tool deformations and wear using the UBE-Technique.

The validity of the method will be proved by an example programme application for tool design of toothed gears and the experimental testing of tools.

Topic(s)

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Call for proposal

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Funding Scheme

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Coordinator

Universität Hannover
EU contribution
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Address
Welfengarten 1A
30167 Hannover
Germany

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Total cost
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Participants (2)