Prevention of thin flash formation in the flashless forging of aluminium under consideration of industrial process parameters and variation of tool-integrated sealing concepts

考虑工业工艺参数和工具集成密封概念的变化，防止铝无飞边锻造中形成薄毛边

• 批准号: 446183957
• 负责人: Dr.-Ing. Malte Stonis
• 金额: --
• 依托单位: Institut für Umformtechnik und Umformmaschinen (IFUM)
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 财政年份: 2020
• 资助国家: 德国
• 起止时间: 2019-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/446183957?language=en
• 关键词: Prevention; thin; flash; formation; flashless

The use of flashless forging in the aluminium forging industry is significantly complicated by the formation of thin flash. Due to its good flow properties, aluminium tends to flow into flow gaps, such as those that exist between punch and die in flashless forging. The formation of thin flash reduces the advantages of flashless forging and prolongs the process chain due to machining post-processing. The challenge is to develop methods to predict and prevent thin flash formation. From the preceding project, on which this transfer project is based, new questions and challenges arise for the prognosis of thin flash formation in industrial processes and the avoidance of thin flash at different tool gap orientations. In the preliminary project, the results were generated that a prediction of thin flash formation is possible and that a tool-integrated sealing concept is suitable for avoiding thin flash. However, these results are not sufficient for industry-related processes because industry-related parameters such as input material tolerances, inconstant temperature control or different tool gap orientations were not taken into account. The results generated from the preliminary project on thin flash prognosis and seal development are to be transferred to industrial processes within this transfer project. The aim of the proposed transfer project is therefore to avoid thin flash formation by varying tool-integrated sealing concepts and to predict thin flash formation taking into account industrial process parameters for flashless forging of aluminium. In order to achieve this goal, we are cooperating with our application partner Otto Fuchs KG. For this purpose, a systematic investigation of the thermal loads, the stress states and the material flow vectors at the tool gap will be carried out in a test tool with four universal tool gap orientations, which will be considered locally. Global process parameters which influence the local influences at the tool gap, are varied. Only on this basis a sealing concept can be meaningfully developed. In order to avoid thin flash, different sealing concepts are developed according to the industrially used tool variants and their sealing effect is investigated. After analysis of the results and selection of a suitable sealing concept, the feasibility of two industry-related investigation tools for the application partner is to be investigated. Finally a new prognosis model can be developed, which is based on material flow vectors and enables predictions for industrial processes. In addition, application-oriented design model for the design of sealings to avoid thin flash will be developed.

在铝锻造行业中，由于薄飞边的形成，闭式锻造的使用变得非常复杂。由于其良好的流动性能，铝倾向于流动到流动间隙中，例如在闭式锻造中存在的凸模之间的流动间隙。薄飞边的形成降低了无闪光锻造的优点，并由于机械加工后处理而延长了工艺链。挑战是开发预测和防止薄闪光形成的方法。从本转移项目所基于的前一个项目中，对于工业过程中薄层闪光形成的预测和在不同刀具间隙方向避免薄层闪光的发生，出现了新的问题和挑战。在初步方案中，预测薄闪光的形成是可能的，工具集成密封概念适合于避免薄闪光的形成。然而，这些结果对于与工业相关的工艺来说是不够的，因为没有考虑与工业相关的参数，如输入材料公差、不恒定的温度控制或不同的刀具间隙方向。薄层闪蒸预测和密封开发的初步项目产生的结果将在该转移项目内转移到工业过程中。因此，拟议的转移项目的目的是通过不同的工具集成密封概念来避免薄闪光形成，并在考虑到铝的无闪光锻造的工业工艺参数的情况下预测薄闪光形成。为了实现这一目标，我们正在与我们的应用合作伙伴Otto Fuchs KG合作。为此，将在具有四种通用刀具间隙方向的测试工具中对刀具间隙处的热载荷、应力状态和材料流动矢量进行系统的研究，这将被局部考虑。影响刀具间隙局部影响的全局工艺参数是不同的。只有在此基础上，才能有意义地提出密封概念。为了避免薄飞边，根据工业上使用的工具变体，开发了不同的密封概念，并对其密封效果进行了研究。在分析结果并选择合适的密封概念后，对应用伙伴使用两种与行业相关的调查工具的可行性进行调查。最后，可以开发一个新的预测模型，该模型基于物质流向量，能够对工业过程进行预测。此外，还将开发面向应用的密封设计模型，以避免薄飞边。