Benefit

Benefit

The developed forging stages and induction (re)heating processes were realized and the whole forging line was successfully installed. During the tests of the whole forging line, a lot of information was gained concerning an industrial implementation of the new forging technology. A multidirectional forging is applicable in an industrial environment, allowing for significant material savings on the forging of crankshafts. The flash ratio could be reduced from about 54 % to about 6 % in the real trials, which equals savings of about 3.8 kg steel per crankshaft. Although the relative energy consumption for heating is about 10 % to 15 % higher than in the conventional forging process due to the induction reheating, the energy consumption per part is about 25 % lower, because of the decreased initial material of the crankshaft. The technical information gained in the trials will be used in the near future to improve the technology even further to allow for a stable serial production.

For a batch of this crankshaft of 10,000 parts, the annual savings would be about 34 tons of steel which results in a financial benefit of about 19,000 € per year. Additional 2,000 € can be saved due to the decreased energy consumption. Moreover, the material and energy savings result in annual reduction of CO2 for the developed crankshaft of 274 tons in total, considering the whole life cycle costs.

 

Forging sequence for one of the model products (FEA results)