![]() ![]() Gas-filled spring devices keep the tool assembly closed. ![]() Next, the upper punch starts moving while the lower punch remains stationary. The steel grade for use in the tool was specified as 1.2365 (32CrMoV12-28) and that for the parts was 1.7131 (16MnCr5).ĭuring the closure of the upper and the lower dies, a first flashless metal-forming operation is performed. The tool consists of an upper die, an upper punch (combined forming and punching die), gas-filled springs, a lower die, a lower punch and a release mechanism (Figure 1). For these trials, a Müller Weingarten PSH 265 screw press was used. The die assembly (measuring approximately 21 inches long x 27.5 inches deep x 28 inches high) is designed to fit into a standard forging press. GRF originally funded a project in 2005 that studied “combined shaping and punching processes,” which was followed by a study completed in 2009 that adapted the original concept for use on parts with a longitudinal axis. The tooling concept for the combined flashless forming and punching process was developed for rotationally symmetric parts at Germany’s Institut für Integrierte Produktion Hannover gGmbH (IPH) within the auspices of the German Research Foundation (GRF). The combined forming and punching process is applicable to rotationally symmetric parts as well as parts with a distinct longitudinal axis.Ĭombined Shaping and Piercing Forging Processes Using a combined precision forming and punching process, high grades of surface quality can be achieved in the through holes, thus superseding additional finishing steps. This results in a decrease in both handling time and production costs since an additional tool is not required. ![]() Through the use of a combined forming and punching process, parts can be formed without flash and punched in a single stroke. This second step extends the processing and handling time, as well as the cost of production, since an additional tool is required for the punching process. Also, forged parts with cavities, holes or apertures are often warm punched and, in many cases, simultaneously deflashed in a second process step. The near-net-shape product formed omits the need for extensive machining. ![]() Since flash does not occur, the requisite amount of raw material is reduced. Flashless precision forging permits both. One way of improving forging operations that helps achieve these key competitive factors is to reduce operating time and material usage during the forging process. Cross-sectional schematic of flashless forming and punching tool ![]()
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