scholarly journals A Report on Metal Forming Technology Transfer from Expert to Industry for Improving Production Efficiency

2021 ◽  
Vol 1 (2) ◽  
pp. 96-103
Author(s):  
Khoirudin Khoirudin ◽  
Sukarman Sukarman ◽  
Murtalim Murtalim ◽  
Fathan Mubina Dewadi ◽  
Nana Rahdiana ◽  
...  
Keyword(s):  
Metal Forming ◽  
Production Efficiency ◽  
Experimental Methods ◽  
Total Efficiency ◽  
Participatory Action ◽  
Progressive Die ◽  
Forming Technology ◽  
The Press ◽  
Expert Team ◽  
Three Stages

This article reports on technological mastery assistance in three small metal forming industries in Indonesia. Problems in the blangking and piercing separately process caused increased production time which resulted in inefficiency cost. Therefore, the expert team aided in metal forming technology through participatory action research (PAR) methods and experimental methods through reverse engineering for several products. The PAR method involves optimal contribution and participation from the industry. Assistance in mastering technology in small metal-forming industries reduces the manufacturing process from seven to three stages, increasing efficiency. The press machine's tonnage capacity must balance with the force blanking/piercing requirement. The minimum press machine requirement is 6.7 tons, and based on the availability of existing press machines, the expert team recommends a 20-ton capacity press machine. Total efficiency can be further increased by implementing full progressive die technology by combining piercing, blanking, and bending processes.

Economic Drive Concept for Flexible Forming Presses

2013 ◽  
Vol 549 ◽  
pp. 255-261 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Richard Krimm ◽  
Thomas Nitschke
Keyword(s):  
Metal Forming ◽  
Multibody Simulation ◽  
Forming Process ◽  
Eccentric Shaft ◽  
Forming Technology ◽  
The Press ◽  
High Investment ◽  
High Dynamic ◽  
Inertia Forces ◽  
Energy Converting

A servo-driven eccentric press is a synonym for innovative and economic metal forming technology. The path-time-characteristic of the ram of servopresses can be adapted to individual requirements of various forming processes. To achieve a high dynamic, the rotary inertia of the drive train should be as low as possible. Thus, a flywheel is not suitable to provide the energy required for both, the forming process as well as the ram kinematic. Hence the eccentric shaft is driven by the electric motor only. As a consequence, the press force has to be provided completely via the torque of the servomotor. High investment costs resulting from the required size of the drive components is a challenge to be conquered. This pushes the costs for the drive components. Another challenge is the unbalanced power consumption of the servomotor. Energy-converting and energy-storing systems are essential to compensate the power peaks resulting from the forming process and inertia forces. Nevertheless, these systems are expensive and reduce the energy efficiency of the press. Facing these challenges, a novel and innovative drive concept for eccentric presses is being developed at the Institute of Forming Technology and Machines (IFUM). The concept and the results of a first multibody simulation are presented in this paper.

Upscaling of foam forming technology for pilot scale

TAPPI Journal ◽  
2019 ◽  
Vol 18 (8) ◽  
Author(s):  
JANI LEHMONEN ◽  
TIMO RANTANEN ◽  
KARITA KINNUNEN-RAUDASKOSKI
Keyword(s):  
Production Efficiency ◽  
Strength Loss ◽  
Pilot Scale ◽  
Foam Density ◽  
Forming Process ◽  
Production Scale ◽  
Forming Technology ◽  
Wet Pressing ◽  
Foam Forming ◽  
Board Industry

The need for production cost savings and changes in the global paper and board industry during recent years have been constants. Changes in the global paper and board industry during past years have increased the need for more cost-efficient processes and production technologies. It is known that in paper and board production, foam typically leads to problems in the process rather than improvements in production efficiency. Foam forming technology, where foam is used as a carrier phase and a flowing medium, exploits the properties of dispersive foam. In this study, the possibility of applying foam forming technology to paper applications was investigated using a pilot scale paper forming environment modified for foam forming from conventional water forming. According to the results, the shape of jet-to-wire ratios was the same in both forming methods, but in the case of foam forming, the achieved scale of jet-to-wire ratio and MD/CD-ratio were wider and not behaving sensitively to shear changes in the forming section as a water forming process would. This kind of behavior would be beneficial when upscaling foam technology to the production scale. The dryness results after the forming section indicated the improvement in dewatering, especially when foam density was at the lowest level (i.e., air content was at the highest level). In addition, the dryness results after the pressing section indicated a faster increase in the dryness level as a function of foam density, with all density levels compared to the corresponding water formed sheets. According to the study, the bonding level of water- and foam-laid structures were at the same level when the highest wet pressing value was applied. The results of the study show that the strength loss often associated with foam forming can be compensated for successfully through wet pressing.

Metal Forming and the Finite-Element Method

1989 ◽  
Author(s):  
Shiro Kobayashi ◽  
Soo-Ik Oh ◽  
Taylan Altan
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Forming ◽  
Computer Aided Design ◽  
The Finite Element Method ◽  
Forming Technology ◽  
Computer Aided ◽  
Deformation Mechanics ◽  
Aided Design ◽  
Element Method

The application of computer-aided design and manufacturing techniques is becoming essential in modern metal-forming technology. Thus process modeling for the determination of deformation mechanics has been a major concern in research . In light of these developments, the finite element method--a technique by which an object is decomposed into pieces and treated as isolated, interacting sections--has steadily assumed increased importance. This volume addresses advances in modern metal-forming technology, computer-aided design and engineering, and the finite element method.

Design and analysis of a novel seven-bar mechanical servo press with dual motors inputs

2016 ◽  
Vol 231 (20) ◽  
pp. 3855-3865
Author(s):  
Chen Liu ◽  
Sheng-Dun Zhao ◽  
Jing-Xiang Li
Keyword(s):  
Metal Forming ◽  
Theoretical Study ◽  
High Capacity ◽  
High Ratio ◽  
Measured Data ◽  
Servo Motor ◽  
Symmetric Structure ◽  
Servo Press ◽  
The Press ◽  
Dynamic Analyses

This paper proposes a novel high capacity servo press system with two servo motor inputs and high ratio force amplifier mechanism for metal forming. First, the press structure was expressed. The force amplifier was made of seven-bar mechanism which possesses quick-return character and high ratio force amplifier. The symmetric structure balanced the force in horizontal direction, and dispersed the forces on two transmission routes. In theoretical study of the new structure, kinematic and dynamic analyses were obtained by examining the geometry of the structure. The performance of press was discussed by example demonstration. Finally, the kinematic experiments and metal forming experiments were carried out on the prototype machine by using grating scale system. The measured data match the theoretical calculation well, which validates the feasibility of this new press mechanism.

Hohl-Quer-Fließpressen mit geregelten Querstempeln*/Hollow lateral extrusion with controlled counterpunches - Improving the branches’ form accuracy by a superposition of a hydrostatic pressure on the forming zone

2015 ◽  
Vol 105 (10) ◽  
pp. 697-703
Author(s):  
J. Wälder ◽  
A. Felde ◽  
M. Liewald ◽  
O. Napierala ◽  
M. Haase ◽  
...  
Keyword(s):  
Hydrostatic Pressure ◽  
Metal Forming ◽  
Feasibility Studies ◽  
Drive Train ◽  
Lightweight Construction ◽  
Form Accuracy ◽  
Lateral Extrusion ◽  
Forming Technology ◽  
New Process ◽  
High Level

Als Beitrag zur Gewichtsreduktion von Komponenten im Antriebsstrang moderner PKWs wird am IFU Stuttgart und am IUL Dortmund ein neues Verfahren zur Herstellung hohler Bauteile mittels Querfließpressen entwickelt. Aufbauend auf ersten Machbarkeitsuntersuchungen werden in dieser Veröffentlichung Maßnahmen gezeigt, mit denen das herstellbare Geometriespektrum hinsichtlich der Verfahrensgrenze gegen Risse erweitert sowie eine Verbesserung der Formabweichung erreicht werden kann.   As a contribution towards a reduction in weight of automotive drive train components, a new process for producing hollow components by lateral extrusion is being developed at the Institute for Metal Forming Technology (IFU) in Stuttgart and the Institute of Forming Technology and Lightweight Construction (IUL) in Dortmund. Based upon first feasibility studies, methods are shown in this publication to extend the spectrum of the producible geometries and to achieve a high level of form accuracy.

The Development/Application of Sheet Metal Forming Technology at Alcoa

1993 ◽  
Author(s):  
E. Chu ◽  
K. N. Shah ◽  
F. Pourboghrat ◽  
K. Chandorkar
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Forming Technology ◽  
Development Application

scholarly journals supervisi pendidikan

2019 ◽  
Author(s):  
Mita sofia
Keyword(s):  
Implementation Process ◽  
School Principal ◽  
Educational Management ◽  
National Education ◽  
Individual Supervision ◽  
Supervision Process ◽  
Expert Team ◽  
Three Stages ◽  
Management Expert

Abstract — The supervision process is a series of activities carried out when conducting supervision. According to the Educational Management Expert Team (2004: 53) in general the supervision implementation process is carried out through three stages, namely planning, implementation and evaluation. Regulation of the Minister of National Education number 41 of 2007 regulates supervision learning process that includes monitoring and supervision. Based on these regulations the follow-up activities of academic supervision can be done by the school principal by providing examples, discussion, training, and consultation. The principal can choose the alternative follow-up activities mentioned above according to the analysis of the results of the academic supervision of the components mentioned above.Educational supervision can be carried out with individual supervision techniques and group supervision techniques. In the current situation, not all supervision techniques that are described below can be implemented by supervisors, but as material readings need to be offered as rasep can be chosen by each supervisor to be used in accordance with the existing circumstances.

Fließpressen hohler Wellen mit Wanddickenvariation/Cold forging of hollow shafts with wall thickness variation – Numerical investigation of a hollow forward extrusion process with adjustable deformation zone

2020 ◽  
Vol 110 (10) ◽  
pp. 684-688
Author(s):  
Alexander Weiß ◽  
Mathias Liewald
Keyword(s):  
Numerical Investigation ◽  
Metal Forming ◽  
Extrusion Process ◽  
Cold Forging ◽  
Thickness Variation ◽  
Part Geometry ◽  
Forming Technology ◽  
Wall Thickness Variation ◽  
The University ◽  
Hollow Shafts

Die Fertigung von Hohlwellen mit komplexer Innengeometrie bedingte bisher meist aufwendige Prozessrouten. Ein am Institut für Umformtechnik der Universität Stuttgart entwickeltes Kaltfließpressverfahren soll nun die wirtschaftliche und flexible Fertigung von Hohlwellen mit Wanddickenvariation ermöglichen. In diesem Beitrag werden das Verfahren beschrieben und die Ergebnisse der numerischen Untersuchung des Einflusses der Werkzeugkinematik auf die erzielbare Pressteilgeometrie dargelegt.   Usually, the production of hollow shafts with complex internal geometry by cold forging requires extensive process routes. A novel cold forging process developed at the Institute for Metal Forming Technology at the University of Stuttgart allows for an economical and flexible production of hollow shafts. This article describes the manufacturing process and presents the results of a numerical investigation for determining the influence of tool kinematics on the achievable part geometry.

Characterization of Direct Laser Metal Forming Technology for the Restoration of Mold Surface

2009 ◽  
Vol 33 (7) ◽  
pp. 681-686 ◽  
Author(s):  
Young-Myung Son ◽  
Jeong-Hwan Jang ◽  
Byeong-Don Joo ◽  
Hong-Sup Yim ◽  
Young-Hoon Moon
Keyword(s):  
Metal Forming ◽  
Mold Surface ◽  
Forming Technology ◽  
Direct Laser

On the Size Effects in Micro/Meso Upsetting of Brass H62 at Elevated Temperatures

2014 ◽  
Vol 621 ◽  
pp. 158-164
Author(s):  
Hao Yan Wang ◽  
Zhe He Yao ◽  
De Qing Mei
Keyword(s):  
Flow Stress ◽  
Sample Size ◽  
Size Effects ◽  
Metal Forming ◽  
Room Temperature ◽  
Production Efficiency ◽  
Elevated Temperatures ◽  
Processing Temperature ◽  
High Production ◽  
Scaling Down

Micro/meso forming, as an emerging manufacturing process for miniature metallic workpieces, has attracted great attention since the 1990s due to its high production efficiency, low material waste and high precision. Due to the so-called size effects in the scaling down, many traditional theories in metal forming cannot be simply applied to the micro/meso forming. In this study, the micro/meso upsetting experiments of Brass H62 were conducted at various temperatures. The stress−strain curves in the experiments were measured and compared. The effects of the temperature and the sample size on the flow stress were discussed. It is found that the flow stress of the material decreased with the decrease of the sample size at room temperature. However, the flow stress of the material may increase with the decrease of the sample size at elevated temperatures. The results indicate that the size effects in the micro/meso forming are significantly affected by the processing temperature.

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