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DECISION SUPPORT SYSTEM FOR THE TRIBOLOGY OPTIMIZATION IN FORGING PROCESSES

Funder: European CommissionProject code: 2014-1-ES01-KA203-004880
Funded under: ERASMUS+ | Cooperation for innovation and the exchange of good practices | Strategic Partnerships for higher education Funder Contribution: 171,013 EUR

DECISION SUPPORT SYSTEM FOR THE TRIBOLOGY OPTIMIZATION IN FORGING PROCESSES

Description

The complexity of the new components being manufactured by different forging processes has generated the need to design advanced and very complex processes, making the forging process conditions reach extreme limits.In this context, extensive research are being carried out to analyze the different parameters and variables and their influence. Research that make us able to overcome these difficulties and to produce highly complex parts in a more efficient way.In previous projects developed by partners a strategic interest was detected within SMEs in research and testing lubricant’s capabilities to improve their forming process. In parallel, there is a significant lack of numerical models to include the effect of lubricants in finite element simulations, technology which are making great strides in facilitating the process design phase.The main objective of the project was to develop a decision support system (DSS) to decide the most appropriate test to describe lubrication conditions as well as to choose the most appropriate numerical models to include lubrication in simulation. The DSS is also complemented with educational materials describing different aspects of both the tribological tests that can be performed to describe tribology systems and numerical models available in commercial codes.The ICT web-based DSS platform supports technician, students and expert in the selection of tribological testing procedures and models for forging processes. Through a web interface the user is interfaced to a Decision Support System (DSS) that supports the decision process thanks to:a) available testing procedures: experimental procedures and laboratory facilities for the investigation of the tribological conditions typical of forging processes (both cold- and hot-forging) are collected to provide a comprehensive database;b) available tribological models: analytical, numerical as well as experimental models to describe the tribological conditions typical of forging processes (both cold- and hot-forging) are collected to provide a comprehensive database;c) development of the decision support system: it has to support the decision approach of technicians, linking the parameters of industrial processes to (i) the laboratory tests for the characterization of the tribological conditions and (ii) to the models for their description and, eventually, implementation in FEM codes.d) Collection of technical specifications of lubricants used for different operation in industrial processes (both cold- and hot-forging).One of the most important part of the project will be to support the features of the DSS with appropriate training material which will be developed describing the processes in terms of i) the general characteristics, the influencing parameters and the typical lubrication policies that are used in industry; ii) the laboratory tests iii) the tribological models. All the project is carried out in collaboration with forging companies which lead to create synergies between industry and education. This collaboration brings together four entities from the regions of Spain, France, Germany and Italy, where the industrial sectors with forging manufacturing have a strong presence. For this reason the partners will contact forging and fastener associations in their countries to involve as much companies as possible in the project. The partnership includes 3 universities and a VET institute, all of them with wide experience in R&D projects.The leader and coordinator of the project, MAI, is a public vocational training institution, working in the metal machining area, PtU has a strong experience in tribology matters , University of Padova, with a strong tradition in manufacturing technology,and University of Valenciennes and Hainaut-Cambrasis will contribute with their strong experience and expertise. Forging companies and industrial associations and potential users of the DSS triblogy platform has been invited to join the network.

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