Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

Die forging

Forming of highly stressed components

The compressive forming process of die forging can be used for manufacturing highly stressed components with and without flash. It is a highly productive manufacturing process primarily used for large batch sizes. The investigations regarding die forging are mainly closely related to the corresponding forming unit, tool system technology and the materials to be formed. In particular, subsequent processes such as pre-forming (cross rolling) are included in investigations of the entire process chain as part of the technology development. In this context it is possible to individually adapt the specific operational conditions and requirements.

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  • Optimized con rods
  • Material efficiency due to joined initial forging shapes
  • High performance tools with quick-change system for cartridges
  • Special materials in hot bulk metal forming
  • Material composites for large engines in shipbuilding

  • Resource-efficient forming process for manufacturing complex components with optimal exploitation of raw material       
  • Die forging can be used as forming process for almost all materials (e. g. conventional steel materials, aluminum and magnesium wrought alloys, nickel-base alloys and titanium alloys)
  • Highly productive manufacturing process with short process times and high automation level of the forming process chains, including temperature finishing treatment of the unmachined forged components
  • Warm forming as energy-efficient process in mass production, particularly for enhancing the microstructure and for reducing the tolerance range of the unmachined forged components
  • Precision forging as special process of hot bulk metal forming for workpieces with highest demands regarding their component properties (dimensional properties, mass characteristics, delicate features)

Development of process chains

  • Market analysis
  • Development of process chain models combined with the required system and machine technology
  • Development of manufacturing concepts, including feasibility studies and manufacturing of prototypes
  • Simulation of the forming process
  • Process optimization/ cost-benefit calculation    
  • Development of characteristic process values of specific materials

Development of specific tool system technology

  • Market analysis
  • Feasibility studies
  • Development of tool technology for presses and hammers
  • Additive manufacturing used for generating tool technology in bulk metal forming
  • Tool simulation
  • Benchmarking
  • Manufacturing of prototypes

Quality assurance

  • Meeting all regulations of the QMS

Machine technology

  • Clutch-controlled screw press SPKA2000 (nominal pressing force 20 MN)
  • Hydraulic double column press HD 315 (nominal pressing force 3,150 kN)
  • Indirect non-ferrous metal press BMP 630 (nominal pressing force 6,300 kN)
  • Hydraulic double column press PYZ 250 (nominal pressing force 2,500 kN)

Software

  • Simulation software “Forge” and “Simufact”
  • Design software Creo
  • Geomagic Design X (formerly Rapidform XOR)