Research and development

New forging process reduces burr percentage from 54 to 7%

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Two-cylinder crankshaft prototypes

The IPH has already been working on multi-directional forging for over ten years and has advanced the process in the course of several research projects. Within the EU project Reforch (Resource efficient forging process chain for complicated high duty parts), the procedure has now been successfully tested for the first time in an industrial environment.

The EU has invested approximately €1.1m in the research project, which was carried out by six companies and research institutes from Germany, Spain, Romania and Turkey. The Institut für Elektroprozesstechnik (ETP) of the Leibniz University Hanover designed the induction heating processes and studied the energy balance of the forging procedure. Spanish company Aurrenak produced the forming tool, which can be inserted into a regular eccentric press and diverts the applied pressure, so that the steel is simultaneously formed from above and from the sides.

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The new process was successfully tested in Turkey: Turkish forging company Omtaş Otomotiv Transmisyon Aksami has already produced prototypes of two-cylinder crankshafts for quads and snowmobiles with the multi-directional tool and now wants to apply the process to the production of other crankshaft types as well. Now it is only a small step to commercial application.

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