Title: Simulation and optimisation of heating stages in a new resource efficient forging process chain

Authors: Sebastian Wipprecht; Egbert Baake; Bernard Nacke; Yulia Pleshivtseva; Stepan Korshikov

Addresses: Institute for Electrotechnology, Leibniz University, Wilhelm-Busch-Str. 4, D-30167 Hannover, Germany ' Institute for Electrotechnology, Leibniz University, Wilhelm-Busch-Str. 4, D-30167 Hannover, Germany ' Institute for Electrotechnology, Leibniz University, Wilhelm-Busch-Str. 4, D-30167 Hannover, Germany ' Samara State Technical University, Molodogvardeyskaya Str., 244, 443100, Samara, Russia ' Samara State Technical University, Molodogvardeyskaya Str., 244, 443100, Samara, Russia

Abstract: The global competition in metal forging is becoming more and more increasing within the last years especially for European small and medium enterprises (SMEs), which are building the main part of the European forging industry. In the frame of the European funded project REForCh a new process chain with a new forging and induction heating sequence is developed. By reducing the input material and changing the forging and heating steps, material and energy consumption and CO₂ emission to the environment can be reduced. The goals of the presented researches are the problem-oriented simulation and optimisation of the pre-heating and re-heating stages in the resource efficient process chain. With the help of two- and three-dimensional numerical simulations the heating steps are configured and optimised. Existing equipment is implemented in the pre-heating step and a new re-heating system is optimally designed and investigated.

Keywords: numerical simulation; optimisation; induction heating; forging process chain; energy consumption; resource efficiency; CO2; carbon dioxide; carbon emissions; metal forging; Europe; small and medium-sized enterprises; SMEs; pre-heating; re-heating.

DOI: 10.1504/IJMMP.2016.078036

International Journal of Microstructure and Materials Properties, 2016 Vol.11 No.1/2, pp.18 - 33

Received: 02 Mar 2015
Accepted: 21 Aug 2015
Published online: 31 Jul 2016 *

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