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

由于薄型闪光的形成，在铝锻造工业中无闪光锻造的使用变得非常复杂。由于其良好的流动性能，铝易于流入流动间隙，例如在无闪锻中存在于冲头和模具之间的流动间隙。薄型闪光的形成，由于加工后处理，降低了无闪光锻造的优点，延长了工艺链。挑战在于开发预测和防止薄闪形成的方法。从之前的项目（该转移项目的基础）来看，工业过程中薄闪的形成预测和避免不同工具间隙方向的薄闪出现了新的问题和挑战。在初步项目中，得出的结果是可以预测薄闪地层，并且工具集成密封概念适用于避免薄闪。然而，这些结果对于工业相关的过程是不够的，因为没有考虑到工业相关的参数，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。在这个转移项目中，关于薄闪速预测和密封开发的初步项目产生的结果将转移到工业过程中。因此，拟议的转移项目的目的是通过改变工具集成密封概念来避免薄闪光形成，并考虑到铝的无闪光锻造的工业工艺参数来预测薄闪光形成。为了实现这一目标，我们正在与我们的应用伙伴Otto Fuchs KG合作。为此，将在一个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、应力状态和材料流矢量进行系统的调查，并将在局部考虑。影响刀具间隙局部影响的整体工艺参数是变化的。只有在此基础上，才能有意义地发展密封概念。为了避免薄闪，根据工业上使用的刀具类型，提出了不同的密封概念，并对其密封效果进行了研究。在对结果进行分析并选择合适的密封概念后，将对两种与行业相关的调查工具用于应用伙伴的可行性进行调查。最后，可以建立一个新的预测模型，该模型基于物料流矢量，能够对工业过程进行预测。此外，还将开发面向应用的防止薄闪的密封设计模型。

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.