+49 2131 82090 Mon - Fri 09:00 - 17:00 Airport City DUS | Peter-Müller-Straße 3 | 40468 Düsseldorf | Germany
+49 2131 82090 Mon - Fri 09:00 - 17:00 Airport City DUS | Peter-Müller-Straße 3 | 40468 Düsseldorf | Germany
Quality
Made in Germany
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Benefits

It is no secret that every machine that runs in automatic mode is more efficient than a machine that runs in manual or semi-automatic mode. But what is the difference between both modes when looking at an open die forging press?

In order to prove the efficiency of the Open-Die Forging Software, we conducted an experiment in a German forge shop. During this experiment, we took a 12 ton ingot of the German steel grade 1.6587 and forged it from 1,000 mm down to 565 mm. We measured the time needed to forge this ingot in manual or semi-automatic mode and compared it with the time needed in fully automatic mode with pass schedules that were calculated with the Open-Die Forging Software.

Here are the results:

Conclusion
With the implementation of Dr. Fister’s Open-Die Forging Software, our customer can save at least 1.5 minutes per ingot. By saving 1.5 min/ingot, our customer can substantially increase the yearly output capacity while still saving money. In other words: the implementation of the software increased the efficiency significantly. The return on investment will be less than 1 year.

Benefits of automation

There are a lot of aspects when optimizing your forging process using the easy2forge software.

Look at some examples:

  • Optimization of initiate and return stroke
  • Optimization of travel step and rotation
  • Forging in dual mani mode in both directions towards and away from the press
  • Optimization of penetration = reducing number of passes
  • Optimization of peel heights
  • Use of measuring passes
  • Reduction of maintenance costs
  • Easy operation for the operators; easy to learn for new operators
  • Less tolerances, better quality

Quality Aspects

Efficiency is not the only important thing in the forging business. You also have to keep an eye on the quality of the product. This not only applies to a single forged piece but also to a series of products that must be forged the same way repeatedly.

Our Open-Die Forging Software offers a variety of functions that deal with quality, namely:

  • Consideration of the minimum reduction as well as the area of the forged piece for the selection of an ingot
  • Automatic generation of an upsetting operation if necessary
  • Consideration of deformation, penetration and minimum forging temperature as functions of the material
  • Optional increased penetration for the first passes to improve centerline consolidation
  • Possibility for an interface to simulation software; e.g. Simufact, Deform, Forge
  • Optimized manipulator step as a function of the selected die, current penetration and depth of the forge piece
  • Consideration of the maximum forging time as a function of the tools (e.g. mandrels)
  • Automatic passes to round corners for high alloyed material
  • Automatic calculation of the number of heats

Material and Energy savings

When considering efficiency, keep in mind that it is not only the efficiency of the press that matters. By optimizing your forging process, you will also benefit from reduced ingot weights and/or reduce the energy required by the furnaces.

Our Open-Die Forging Software means:

  • Higher efficiency leads to higher furnace load and reduced energy costs per ingot
  • Higher efficiency reduces the number of heats
  • Fewer number of heats reduce energy costs
  • Lower number of heats reduce the material costs due to less scale
  • Optimized ingot selection can reduce material costs

Visit us at 2nd EUROFORGE conFair at Sep 28+29 in Bilbao, Spain.

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