Prevention of thin flash formation in the flashless forging of aluminium under consideration of industrial process parameters and variation of tool-integrated sealing concepts

• Applicant: Dr.-Ing. Malte Stonis
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2020 to 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 446183957

• Final Report Year: 2024

Final Report Abstract

In the research project "Thin flash avoidance in the flash-free forging of aluminum under consideration of industry-related process parameters and variation of tool-integrated sealing concepts", FliDiAl for short, the basics of the industry-related development of sealing elements for precision forging were investigated in the reporting period mentioned. The aim of the research project was the reduction and long-term avoidance of thin flash, in other words the flow of material into tool gaps. Aluminum is particularly susceptible to the formation of thin flash, as the many slip planes of the grid structure result in a high forming capacity. The simulative investigation of process parameters and different sealing concepts (WP 1) provided initial insights into a suitable sealing concept. An adapted rectangular seal geometry was selected under the consideration of thin flash avoidance combined with a long service life. By constructing a test tool and subsequently carrying out tests, different parameter variations were tested and the assumptions from WP 1 were verified (WP 2 & WP 4). The effectiveness of a seal in industrial tools was partially demonstrated by a simulative study (WP 3). Multi-dimensional seals in particular posed a challenge here. New basic knowledge for the use of seals in precision forging processes was gained on the basis of the simulative and experimental investigations. The knowledge gained was incorporated into a new design model (WP 4).

Publications

• Dichtungsentwicklung für das Gratlosschmieden von Aluminium. In: phi – Produktionstechnik Hannover informiert, Newsletter Nr. 30 / März 2021. ISSN: 2198-1922
  Martini, A.
  
• Prozessoptimierung durch Flittergratvermeidung. Zeitschrift für wirtschaftlichen Fabrikbetrieb, 117(11), 754-757.
  Martini, Alexander; Doede, Nils; Kriwall, Mareile; Stonis, Malte & Behrens, Bernd-Arno
  
• Flittergratvermeidung durch Dichtungsentwicklung. Zeitschrift für wirtschaftlichen Fabrikbetrieb, 119(7-8), 507-510.
  Doede, Nils; Kriwall, Mareile; Stonis, Malte & Behrens, Bernd-Arno