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Pre-forming by cross wedge rolling to increase efficiency

Presentation held at 30th Forging Industry Technical Conference, 8. und 9. September 2014, Plymouth, MI
Zwischenformung mittels Querkeilwalzen zur Steigerung der Wirtschaftlichkeit
: Steger, Jürgen

Präsentation urn:nbn:de:0011-n-3235085 (3.1 MByte PDF)
MD5 Fingerprint: 09266d9428b4d69a8d1b9ced6d959e83
Erstellt am: 24.1.2015

2014, 22 Folien
Forging Industry Technical Conference <30, 2014, Plymouth/MI>
Vortrag, Elektronische Publikation
Fraunhofer IWU ()
Zwischenformung; Querkeilwalzen; Gesenkschmieden; cross wedge rolling; forging; pre-forming

Intermediate forming aimed at distributing the material volume contributes to better utilization of the material, reducing the amount of energy required for heating and improving quality by using near-net-shape geometries. A range of different forming operations exists for realizing material distribution.
This paper gives an overview of the process technologies used for distributing the material in an intermediate forming stage in forging of light metals such as aluminum, titanium and titan-aluminide, and also illustrates their application areas. The technique of cross wedge rolling is an incremental forming process with open groove and partial force exposure. The wedge shape for forming is generated by using wedge-shaped tools or due to controlled axial feed of simple round tools.
Research and technology development in the field of bulk metal forming at the Fraunhofer Institute IWU Chemnitz has resulted in a number of successful applications of cross wedge rolling in preforming.
The development of a single cross wedge rolling operation will save other forming operations in the production of titanium aircraft components. A considerable reduction in cycle times and in manufacturing costs is the result of the shortened process chain. Additionally, the number of ancillary processes, such as heating, adjustment and lubricant application are reduced as well.
Another application of cross wedge rolling resulted in enhanced preforming for subsequent flash-poor forging of aluminum powertrain components. The challenges of controlling the material structure and tight temperature requirements were met by a flow-optimized work-piece design in combination with a heated rolling tool.
There is evidence demonstrating the bulk metal forming of gamma-titan-aluminide by cross wedge rolling followed by impression die forging using the same heat.