Optimization of Material Utilization by Developing a Reliable Design Criterion for Tool Construction in Cross-Wedge Rolling

Author:

Kramer Patrick1,Karaman Abdulkerim1ORCID,Marré Michael1ORCID

Affiliation:

1. Labor für Massivumformung, South Westphalia University of Applied Sciences, 58644 Iserlohn, Germany

Abstract

The massive forming industry in Germany produces around 1.4 million parts every year, which are mainly used in safety-relevant areas such as the automotive industry. The production of these parts requires a considerable amount of energy, much of which remains unused and causes high CO2 emissions. An efficient approach to reduce these emissions and improve material utilization is cross-wedge rolling, which enables efficient material utilization but is limited by the so-called Mannesmann effect, which leads to unwanted material defects. This paper describes the development and validation of a safe design criterion for cross-wedge rolling tools in order to avoid material damage caused by the Mannesmann effect and thus increase resource efficiency in forging. Based on simulation-supported investigations and experimental tests, process maps are created for various materials. The validation is carried out both in an experimental test facility with real tools and in an industrial production facility, which leads to a significant reduction in excess material and CO2 emissions. The results show that the full resource potential of cross-wedge rolling can be exploited by optimizing process parameters and tool geometries.

Funder

German Federal Environmental Foundation

South Westphalia University of Applied Sciences

Publisher

MDPI AG

Reference18 articles.

1. Industrieverband Massivumformung e.V. (2023). Evaluation of the Official Production Statistics for the Forging Industry in Germany: IV and I–IV Quarters 2023 Preliminary, Industrieverband Massivumformung e.V.

2. Olschewski, I., and Rothgang, M. (Final Report on the IGF Project No. LN 25. Massiver Leichtbau: TP5: Potentials, Technology Transfer, Innovation Barriers, 2018). Final Report on the IGF Project No. LN 25. Massiver Leichtbau: TP5: Potentials, Technology Transfer, Innovation Barriers.

3. Marré, M., Hermanns, H., and Frank, S. (Increasing Resource Efficiency in Forging by Securing and Expanding Process Limits in Cross Wedge Rolling: DBU Final Report 33234/01-24, 2019). Increasing Resource Efficiency in Forging by Securing and Expanding Process Limits in Cross Wedge Rolling: DBU Final Report 33234/01-24.

4. Industrieverband Massivumformung e.V. (2017). Massive Forming in Germany: An Energy-Intensive Energy-Efficient Industry, Industrieverband Massivumformung e.V.

5. Design of a Genetic Algorithm for Preform Optimization in Hot Forging Processes;Kampen;Int. J. Mater. Form.,2020

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