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Cross wedge rolling and bi-directional forging of preforms for crankshafts

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Abstract

Preforming is an essential step in flashless forging processes. This paper describes the development of a four stage process chain for flashless forging of a two cylinder crankshaft with pin and flange. The process consists of cross wedge rolling, lateral extrusion, bi-directional forging and final forming, with cross wedge rolling being the essential step. The finite-element-analysis (FEA) performed with the software Forge 3 and experimental tests are executed with different process parameters, like billet and tool temperature, rolling velocity and steel. To reduce process steps, like lateral extrusion, a direct combination of cross wedge rolling and bi-directional forging is analysed with FEA-software Forge 3 for a one cylinder crankshaft without pin and flange. The one cylinder crankshaft is selected to reduce development effort. The results of the FEA give suitable forming angles α for cross wedge rolling and several geometric parameters for a modification of the bi-directional tool.

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Acknowledgments

The authors thank the German Research Foundation (Deutsche Forschungsgemeinschaft—DFG) for the funding of the Collaborative Research Project 489 “Prozesskette zur Herstellung präzisionsgeschmiedeter Hochleistungsbauteile” and the research project “ProKomb—Prozesskombination des Querkeilwalzens mit der mehrdirektionalen Umformung” (DFG STO 1011/5-1).

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The authors declare that they have no conflict of interest.

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Authors and Affiliations

  1. IPH - Institut für Integrierte Produktion Hannover gGmbH, Hannover, Germany

    Matthias Meyer, Malte Stonis & Bernd-Arno Behrens

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  1. Matthias Meyer
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  2. Malte Stonis
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  3. Bernd-Arno Behrens
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Correspondence to Matthias Meyer.

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Meyer, M., Stonis, M. & Behrens, BA. Cross wedge rolling and bi-directional forging of preforms for crankshafts. Prod. Eng. Res. Devel. 9, 61–71 (2015). https://doi.org/10.1007/s11740-014-0581-8

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  • DOI: https://doi.org/10.1007/s11740-014-0581-8

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