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Research and development a new technology of cold precision forming as replacement the cutting operations

Aim of project is research and development of technology which replaces secondary and chip-machining operations during production of stamped parts for automotive and electro-technical industry. The secondary operations will be replaced by precise, cubical cold forming operations.

Majority of parts for automotive and electro-technical industry request not only clear and smooth cutting periphery area and precisely tolerated inlets, but more often these parts contains different cubical formed elements. Among the elements we can understand circle and shape dips, protrusions, whole placements or chamfers on periphery edges of the holes. Dimensional requests are often connected with these various chamfers and drifts and they need to be produced in secondary operations, mainly using chip-machining. The main technical solution of the project is to supply several various technologies for precise part production by one technology - the progressive forming technology. In specific, utilisation of advantage in technology of surface and cubical forming. All the above mentioned demands for quality, precise and final shape of produced part can be reached in a special stamping tool. Such stamping tool must be designed as a combined progressive stamping tool for precise cutting, which is designed for production on a tree-active press. The combined progressive stamping tool integrates the described technologies of surface and cubical forming. The technology of surface forming is in the tool on the precise cutting principle. The shape elements of the part are, in the tool, solved by clear cubical transformation or, in a combination with consequential surface forming (pre-cutting, final cutting, etc.). The main aim of the project is research and development of technology which replaces secondary chip-machining operations during production of stamped parts for automotive and electro-technical industry. The secondary operations will be replaced by precise, cubical cold forming operations, which will be directly implemented into a progressive stamping tool. Because such parts are very often produced from thicker materials and they are tolerantly demanding, we will use stamping tools for precise cutting - type fine-blanking, which can run on presses by company FEINTOOL. We focus on main aims in the project: 1) Replacement of a costly foreign technology by our own technology. Swiss company FEINTOOL, which produces progressive presses, is also involved in the implementation of stamping operations into the cutting tools, however they do not provide for free any strategic experience and theoretical plus practical knowledge from this area. It is possible to purchase a quite expensive solution always only for one particular part, because the company invested very high costs into development of the technology during last ten years. The aim of our project is to develop own technology, which will be, for our company and co-operational partners more price affordable than costly technology by Swiss FEINTOOL. To achieve high efficiency of the production we need: - To develop a mathematical model for calculation of a specific cubic transformation and material deformation; - To develop a supporting software device for technological proposal support; - To define an optimal parameter combination: material-cubical element-grease. 2) Energy savings, lower ecological load. Our project aims to develop such technology, which enables to eliminate up to 2/3 of secondary operations from production process. Only the last de-burring operation will remain, so it will lead to total decrease of energy intensity of production. The elimination of chip-machining operations also makes lower ecological load for environment - the necessity of cooling and thread liquids for machining is omitted. Savings factors: - elimination of secondary operation done by chip-machining; - need for cooling and thread liquids in omitted; - total production time decrease; - elimination of semi-operation handling; - lower percentage of waste material with a better opportunity for further selling and utilisation. 3) Financial cost saving. The elimination up to 2/3 of secondary operations from production process lead to financial cost savings, which finally positively affects the total end product price. The basic financial reduction is connected with a generally lower energy intensity and higher productivity of the new technology. Savings factors: - elimination of secondary operation (savings for investments into chip-machining machines); - high productivity in continual production processes; - law energy intensity (savings for electrical energy for chip-machining machines); - lower material costs (higher waste material utilisation - chips are omitted); - savings for cooling emulsions. The substitution of an expensive foreign technology by our own one. The new technology will be usable for a wide range of production units. Price for foreign technology for one particular part production can reach several million (the purchase of the foreign technology for 4-5 parts is similar to a complete budget for a whole project). For a particularly chosen machine part "Flange" we can estimate the savings for 10,- - 12,- CZK (50%) on one piece - significant competitive advantage.
Acronym: 
FINETOOL
Project ID: 
6 737
Start date: 
01-11-2011
Project Duration: 
46months
Project costs: 
1 420 000.00€
Technological Area: 
Forming (rolling, forging, pressing, drawing)
Market Area: 
Machine tools, other metal working equipment (excluding numeric control)

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