Road Map

Road map

Development of the process chain

In the initial work package, the products and production equipment was analyzed and categorized according to:

 –   crankshaft material and weight,
 –   geometrical crankshaft and work piece dimensions,
 –   mass distribution,
 –   tolerance requirements of the final geometry,
 –   surface properties,
 –   current conventional production sequence/necessary equipment and
 –   production volume (batch size).

For the model products, two flash reduced forging sequences were developed. One of these sequences was tested in an industrial environment. To provide the base for applying the technology to other crankshaft geometries, similar crankshafts were identified.

  

General process chain

General process chain

 

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

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

 

Development and installation of the equipment

The development and installation of the equipment was focused on the multidirectional forging operation and the intermediate heating/reheating process.

Parallel, the heating system was developed at the Institute for Electrothermal Processes (ETP) in cooperation with the heating-apparatus producer EMA-TEC GmbH.

In separate steps, the equipment was tested and installed. The process sequence was simulated and the tools were designed and machined.

Verification of the process and the equipment capability

After the equipment has been tested separately and the whole production line has been linked, the process limits were investigated to find the optimum process parameters.