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Influence of the forming angle in cross wedge rolling on the multi-directional forging of crankshafts

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Abstract

In each industrial process for the production of crankshafts a low energy demand and a fast processing time are required. Crankshafts have a very complex geometry and are forged with a high percentage of flash compared to other forging parts. Recent research showed the feasibility of a flashless forging of crankshafts. One way to forge a flashless crankshaft within three steps is to use cross wedge rolling, multi-directional forging and final forging. This paper presents the investigation results regarding the influence of the forming angle α in cross wedge rolling on different parameters at multi-directional forging. First, the state of the art is presented. As a basis for the investigations the process development and tool design of cross wedge rolling and multi-directional forging are described. Afterwards the paper’s results regarding the influence of the forming angle α on flash generation, billet temperatures, forming degree, forming forces and effective strain will be presented as a parameter study. Generally, flash is generated because a rotation-symmetric billet is forced into an asymmetric movement. The influence of an increasing forming angle leads to a higher amount of flash at the bottom of the crankwebs.

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Acknowledgment

The authors thank the German Research Foundation (Deutsche Forschungsgemeinschaft ¬– DFG) for the funding of the research project “ProKomb – Prozesskombination des Querkeilwalzens mit der mehrdirektionalen Umformung” (DFG STO 1011/5-1).

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Authors and Affiliations

  1. Institute of Metal Forming and Metal Forming Machines (IFUM), Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    Bernd-Arno Behrens

  2. Institut für Integrierte Produktion gemeinnützige GmbH Hannover (IPH), Hollerithallee 6, 30419, Hannover, Germany

    Malte Stonis & Neelam Rasche

Authors
  1. Bernd-Arno Behrens
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  2. Malte Stonis
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  3. Neelam Rasche
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Corresponding author

Correspondence to Neelam Rasche.

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This study was funded by the German Research Foundation (Deutsche Forschungsgemeinschaft – DFG, STO 1011/5–1). The authors declare that they have no conflict of interest.

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Behrens, BA., Stonis, M. & Rasche, N. Influence of the forming angle in cross wedge rolling on the multi-directional forging of crankshafts. Int J Mater Form 11, 31–41 (2018). https://doi.org/10.1007/s12289-016-1326-3

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  • DOI: https://doi.org/10.1007/s12289-016-1326-3

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