The integration of sensors in forming tools 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.
The solution is presented by the development of a tribologically resistant multi-functional sensor system deposited directly on forming-tool surfaces 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 and wear detection are to be integrated into the sensor design. The sensory punches will be coupled with embedded multi-sensor electronics and then tested during reverse extrusion.
With successful completion of the project, multi-sensory forming-tool components will be available which will enable the monitoring of cold-forging processes and support the predictive maintenance of tools. In addition, process understanding will be deepened with the aid of measurement data concerning wear in the main load zones, the forming force and the temperature distribution along the punch land.