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

Forming machine tools

Machine, technology and periphery

In the area of “Forming machine tools” we offer our competencies of planning, development, design and property analysis of assemblies for forming machines or plants, including the corresponding handling equipment.

The numerical calculation, analysis and simulation of individual components up to complex machine structures and process cycles have become increasingly indispensable for the development of modern and competitive products. Our services regarding the analysis and simulation of forming machine tools comprise designing and testing in the development of machines as well as analysis of existing plants.

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Machine analyses

  • Experimental machine analyses
  • Property analyses of presses
  • Novel method for measuring force distribution in forming machines

Servo press technology

  • Adaptable test station for servo presses

Machine development

  • Spin extrusion machine BDM2000
  • Retrofitting of a molding press

  • Reduction of product development times
  • Structural optimization
  • Representation of complex kinematic relationships (collision analyses)
  • Predetermination of process cycles
  • Reduction of downtimes
  • Enhancing dynamics
  • Innovative drive systems

Process chain development

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Planning and technological dimensioning of processes, tools and machines
  • Fundamental investigations
  • Experimental development of characteristics
  • Plant planning and concept development for press plants, including simulation of the part throughput and possible yield
  • Product development, design and project planning of selected assemblies of forming machines, for example structure components, main drives and auxiliary drives, automation technology
  • Theoretical and experimental property analysis of the static and dynamic behavior of forming machines

Development and evaluation of forming machine tools

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation
  • Development and testing of prototypes
  • Application, simulation, control, diagnosis and maintenance of fluidic drives
  • Development of electrical drive assemblies
  • Metrological analysis using laser measuring system
  • Analyzing energy efficiency of plants and machines
  • Experimental identification of static and dynamic behavior of machine tools and forming tools
  • Assessment and optimization of static and dynamic machine behavior by analyzing critical spots and deducing potentials for improvement
  • Analysis of failure causes
  • Calibration of machine tools and forming tools
  • Realization of operational vibration analyses and acoustic examinations

Quality assurance

  • Static and dynamic calculations
  • Process monitoring in cutting and forming
  • Machine monitoring according to predictive, condition-based maintenance (condition monitoring)

Machine technology

  • Clutch-controlled screw press SPKA2000
  • Axial closed die rolling machine AGW80/250
  • Flat tool holder cross rolling machine FBQ100/1600
  • Round tool holder cross rolling machine RBQ1000
  • Spin extrusion machine BDM2000
  • Several hydraulic presses with press forces ranging from 50 kN to 16,000 kN
  • Two hydroforming presses (4,000 bar; press force: 15,000/50,000 kN)
  • Two-rolls profile rolling machine PWZ Spezial, Rollex XL-HP and PR15 HP
  • Three-rolls profile rolling machine 3PRD
  • Rotary swaging machine HA 100-1 SUE LH-NC

Software

  • ProEngineer (parametric 3D-CAD software)
  • Autodesk Inventor (parametric 3D-CAD software)
  • One Space Designer (3D-CAD Software software for dynamic modeling)
  • Auto CAD (2D – 3D-CAD software)
  • Eplan Fluid (Simulation of circuits of fluid technology systems)
  • SimulationX (CAE software for simulating physical-technical systems and plants)
  • IDEAS (FE structural analysis, flow simulation)
  • ANSYS (FE structural analysis, flow simulation)
  • ITI-SIM (multibody simulation)
  • Matlab/Simulink (controller synthesis)