Wickert has developed an assembly line, which combines forming and hardening in one single operation.
Similar assembly lines usually consist of a high-temperature furnace and a forming press with integrated quenching. Water, polymer or hardening oil can be used for quenching.
When combining forming and quenching, a metal sheet is heated up to a temperature of about 950 °C. It is then placed into the forming press, where it is formed and quenched within the forming tool. The forming tool is modified accordingly.
This way parts, like wear parts for agricultural machines, can be produced at a lower investment and production cost, compared to conventional manufacturing. With conventional manufacturing the work piece is formed first and then in a second step it is placed in a second press to harden the material. This extra time is saved using the combined method.
Another advantage is the quick contact between material and quenching medium, ensuring quenching at the right temperature. That usually prevents the development of ferretic structures. That is a big advantage when working with thin boards of about 2 - 4 mm.
The hardening time can be reduced by up to 50% with this process. The return flow of the quenching medium is specifically captured in the tool clamping plates and directed in a controlled manner to the filtration systems.
This guided return enables a classic flow restriction, which creates a defined internal pressure within the forming or hardening tools. This targeted internal pressure shortens the so-called "Leidenfrost phase" – the vapor film formation that initially delays direct cooling.
The transition to the effective boiling phase thus occurs much earlier: the insulating vapor layer collapses more quickly, the quenching medium comes into direct contact with the component sooner – and the maximum cooling effect is triggered rapidly.
The result: Significantly shorter process times with consistently high process reliability.
