How to save 20 percent steel with forging technology

We can forget many components in the combustion engine, so that they can withstand the high loads. A high material loss at the traditional drop forging. German scientists have now developed a new process with which this can be reduced by one/fifth. Produce polluting but unduly, because this significantly more material and energy is consumed than is actually necessary. And it’s also expensive. The Institute has developed a more economical process for integrated production. Hanover (IPH) together with partners from Europe found the ways which can reduce the wastage by 20 percent.

Drop forging is the classic save 20 percent steel with forging technology

A common rail is part of an advanced fuel injection system for internal combustion engines. The steel tube is used as common fuel high pressure storage are connected to the injectors for supplying the cylinder in the piston.

Common rails are manufactured today in the classic die forging process. In a blank steel is heated and placed in a two-part form, they die on good 1200 ° C. In the forging process, the two halves of the die are pressed together and the hot metal flows into the mold. Side of excess steel swells out when this die forging process and forms ridge that as is removed after cooling of the component.

No Ridge during cross wedge rolling

This procedure while ensuring that no voids remain in the form, but also an unprecedented battle of material. So a common rail required for a truck 9.3 kg stainless steel. Two forging steps, where each is a ridge, the final common rail weighs only six kilograms. 3.3 kg have been lost over the ridge.

This is also different: with the manufacturing process developed, where the component by means of cross wedge rolling is preformed and then finished forged. The hot metal is rolled it between two wedges in the form. When this cross wedge rolling, no Burr is created.

20 percent less steel needed

And yet significantly saves on raw material: according to a computer simulation of the scientists, 20% less on stainless steel is required for a complete common rail for trucks.

Though still material is lost even when the cross wedge rolling. But meet for the production of common Rails 7.5 kg instead of the original 9.3 kg stainless steel. Also the new manufacturing process saves even more energy must be heated according to less steel to the required forging heat of 1200 ° C.

Expensive and complicated processes

Energy and material saving cross wedge rolling was hardly used. It has a simple reason: the processes are complicated and with use of expensive tools. Previous cross wedge rolling equipment in round jaw design is worthwhile only for very high quantities. In the current research project funded by the European Union “CoVaForm“, the scientist at the IPH have now developed a compact cross wedge rolling machine in flat baking type, which costs only one-tenth. It is very interesting also for small and medium-sized forging company.

How to save 20 percent steel with forging technology
With this cross wedge rolling machine 20 percent material can be saved during forging. And the acquisition of particularly compact cross wedge rolling apparatus in flat baking type costs only one-tenth of what is paid for on the market existing devices. The latter are suitable only for large companies that produce in large quantities. The invention of researchers but is worth also for small and medium-sized enterprises. The IPH apparatus is used in future at a forging company in Turkey. Photo: IPH

Implants made of titanium

This machine by the IPH can produce not only the forms for common Rails, but also drive shafts, connecting rods and a lot more elongated components. It is not just theory, simulation and research. Cross wedge rolling apparatus from the House of IPH is currently established in Turkey by IPH engineers. A Turkish blacksmith company wants to forge that titanium implants.