Multi-sensory tools for cold forming

Challenge 

The integration of sensors on a forming punch creates challenges owing to high process forces, short cycle times and contaminated environments, as a result of which process data is often only recorded to a limited extent via ram force and travel. For the application of thin-film sensors directly onto the tool surface, tribologically adapted coating systems must therefore be developed and tested.

Solution 

The solution is presented by the development of a tribologically resistant multi-functional sensor system deposited directly on the surface of the forming punch for the real-time analysis of process variables during the pressing process. The thin-film sensor system developed at the Fraunhofer IST is to be used to measure the temperature distribution in three different areas along the punch. In addition, punch forces can provide additional process information via an integrated measuring disc and wear detection on the stamp collar. The sensory forming punches will be coupled with embedded multi-sensor electronics and then tested during reverse extrusion.

Added value 

The sensory forming punches developed in the project enable the measurement of temperature (distribution) during cold forging. In addition, the process understanding is deepened with the aid of measurement data concerning tool wear in the main load zones. In this way, the basis for digital process monitoring is integrated directly in the tool and the process understanding is deepened.