August 2024 Volume 6

ENERGY

According to the results of this project, which can be taken from the publications [3, 4, 5], axial forming can be regarded as an economical alternative forming technology. In order to demonstrate the environmental potential of cold metal forming through innovations and improvements along the entire process chain described above, a comparison of the CO2 footprints calculated by FRED was carried out. The Software FRED [6], which specializes in forming processes, can calculate the shortened forming process chain as well as the fully mechanical production of the rotor shaft from Figure 2. The corresponding comparison in Figure 4 shows that a workpiece weight of 2.6 kg is required for a machining process from a tube and that a material waste of approx. 50% must be expected during this process. This amounts to approximately 3.1 kg of CO2 footprint for the entire production process, including the raw material. In comparison to machining, the Felss process chain requires a workpiece of only approx. 1.4 kg and produces approx. 2 kg of CO2 including all process steps. The CO2 saving per compo nent is therefore 35% or 1.1 kg per component. When converted to a conventional series production of this rotor shaft with 200,000 to 400,000 components per year, the application of such innovative cold forming processes can save more than 200,000 kg of CO2 per year during production and thus, make a greater contribution to environmental protection.

[4.] Missal, N; Schwertel, S.; Ludwig, M.: The next level of axial forming for a sustainable component and process chain design. Conference proceeding International Conference on Gears 2023, VDI-Berichte volume 2422, p.1765-1776, VDI-Verlag, Düssel dorf, 2023, http://dx.doi.org/10.51202/9783181024225-1765 [5.] Missal, N.; Schwertel, S.: Schrägverzahnungen durch Axialformen: Neue und nachhaltige Wege in der Massivumformung. massivUM FORMUNG, April, 2024, Industrieverband Massivumformung e.V., Hagen, 2024 [6.] Raedt, HW.: Klimapfad Massivumformung - Wege zu CO2-freien Komponenten. ATZ Automobiltech Z 124, p.26–31 (2022). https://doi.org/10.1007/s35148-022-0831-6

Contact persons:

Andrew Rush Sales and Service Manager North America Felss Systems GmbH Phone: +1 262-374-3369 Email: Andrew.Rush@felss.com

Andreas Wächter Area Sales Manager Felss Systems GmbH Phone: +4917610219978 Email: Andreas.Waechter@felss.com

Figure 4: Comparison between conventional and Felss process chain. Literature: [1.] Presse- und Informationsamt der Bundesregierung: Neuzugelas sene Pkw ab 2035. EU-Umweltrat: Nur noch CO2-frei fahren. (03.04.2024) https://www.bundesregierung.de/breg-de/schwer punkte/europa/verbrennermotoren-2058450 [2.] Petri, R.; Jaeger, M. B.; Lahdo, N. et. al.: Antriebsportfolio der Zukunft. Ein Meinungsführer/-innen-Report aus Politik und Wirtschaft. VDE study, p.9, VDE Verband der Elektrotechnik Elektronik Informationstechnik e. V., Frankfurt, 2021 [3.] Missal, N.; Schwertel, S.: Innovative cold metal forming processes for a sustainable future – Moving forward with helical gear drive components in a resource and energy-efficient way. Dritev 2023, VDI-Berichte volume 2420, p.295-306, VDI-Verlag, Düsseldorf, 2023, https://doi.org/10.51202/9783181024201

FIA MAGAZINE | AUGUST 2024 14