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  • Metal forming for the manufacture of lightweight components

    The complexity of the parts and assessment of critic formability of lightweight metals is challenging in hot stamping. The singularity of the available equipment combined with numerical methods enables the optimization or the process window design for that materials. Rotary forging is the other studied technology that fulfills the resource efficiency trend. It uses incremental deformation locally with the material to near net shape results, minimizing machining and welding operations. Prototypes are manufactured under preindustrial domain for achieving robust production.

      MOST OUTSTANDING EQUIPMENT AND COMPONENTS

    • 800 T Loire hydraulic press
    • DENN Trace manufacturing system designed to the acquisition, monitoring and record of main relevant process data of rotary forging.
    • Heating furnace for huge dimensions component
    • Rotary forging experimental unit with 350 kW motor and 12 KNm as maximum torque. This unit is set inside the hydraulic press (800 T).

    SERVICES OFFERED BY THE ASSET

    Design and optimization of forming processes

    The activities are related to development of new forming processes including the process window definition for novel materials or the optimization of existing metal forming processes.

    Hybridization of rotary forging with other processes

    The activities are related to research and development of hybrid processes and their application to existing forged components. Examples: 1) Combination of rotary forging and flowforming to manufacture a lightweight wheel rim without welding seams and 2) Rotary forging with conventional forging to obtain a forged teeth gear.

    Rotary forging design for net-shape parts

    The activities are related to development of rotary forging processes and their application to existing forged components. Tooling design is also included.

    ENTITY MANAGING THE ASSET

    FUNDACIÓN TECNALIA RESEARCH & INNOVATION
    Contact person:
    Fernando Liebana