The objective of the project EMuDig 4.0 was to achieve a "significant increase in efficiency for bulk forming processes through development and integration of digital engineering technologies along the entire value and process chain”. Therefore, multiple digital systems have been developed and analyzed by the research partners. The systems are used for the assistance of the
workers throughout the forging process. Within the subproject "Predictive Maintenance", the machines used for serial production of forged wheels were equipped with additional hardware and thereby integrated into an overarching data infrastructure system. By doing so, the operating behavior and maintenance intervals of the forging presses could be evaluated and the machine functions could be monitored in real time. As a result, maintenance routines could be conducted as actually needed instead of as scheduled.
As part of the subproject "Predictive Quality", the scientific partners developed concepts for a continuous digital infrastructure as well as comprehensive routines for data aggregation. Subsequently, various data-driven analysis tools were developed, tested and transferred to the demonstrator projects. This allowed a data-based assessment of interdependencies between process parameters and product properties. In addition, self-learning models could be realized, which enable the analysis and real-time tracking of relevant key figures and parameters within a plant network. Derived web assistance systems do now offer an active support to the machine operator by calculating optimized machine parameters. The result of the subproject "production tools", is a model for the so-called tool-life-prediction of a forging tool and it was developed and specified to the specific requirements of both demonstrator projects. For the first time, an overall consistent data and information basis was created with relevant KPI´s used for the production of forged parts. This information basis is now available to the employees in the production department. However, it can also be used by departments such as costing, work preparation or maintenance. After completion of the project, the partners are now working on the transfer of the results to other production lines and locations and on the expansion of the tools with regard to parameters and process dynamics.