Third Party Funds Group - Sub project
Start date : 01.04.2025
End date : 30.09.2027
Cold forging has been pioneering for more than 2000 years. In order to
address current ecological and economic challenges and reduce CO2 emissions, technical components are
primarily produced using cold forging. This combines advantages such as the
elimination of energy-intensive heat treatment and surface scaling. In order to
meet diverse requirements such as high load-bearing capacity and eco-friendly
production, the use of tools with complex internal geometries is necessary to
enable the production of near-net-shape components. High contact pressures and
tensile stresses due to high yield stresses lead to high loads on tools. This
can lead to fatigue failure, resulting in economic disadvantages that are
associated with an inhibition threshold for the use of efficient cold forging
processes.
The goal of the project partners is to develop concepts for
extending tool life of cold forging tools. Using numerical simulation models,
it is possible to analyse tool loads in detail. To achieve this objective,
geometric and mechanical component properties are analysed and used as a
database for tool stress. Integrated into a simulation model, this data is used
to determine the tool life. In order to validate the accuracy of the
predictions, the methods are transferred to industrial processes.
The calculation and subsequent extension of tool life
contribute to more economical production of cold forged components and promote
the spread of eco-friendly manufacturing technologies in Bavaria as a business
location.