This article presents the results of a comparative analysis performed with respect to the wear of tools used for the extrusion of a clay strand (for ceramic roof tile) made from two materials: steel NC11LV and steel Hardox 600. The aim of the studies was to determine the causes and mechanisms of wear as well as to evaluate the possibility of choosing the optimal material, mostly in respect to its resistance to intensive wear as well as an increase in the operation time. The results of the conducted investigations included: an analysis of the technology, thermovision measurements of the forming process, a macroscopic analysis combined with 3D scanning of the worn tools, ball-on-disc tests of the sliding wear resistance and hardness measurements. The obtained results demonstrated that the tools made of steel NC11LV were much less worn than those made of steel Hardox 600, as the operation time for the NC11LV steel tools was almost three times longer. The results of the ball-on-disc tests showed a similar manner of wear for both materials (with the working temperature of about 50 °C). The higher durability of the tools made from steel NC11LV can be an effect of a slightly lower coefficient of friction in the initial period of operation as well as the presence of hard carbides, which means increased hardness and thus also higher wear resistance at working temperatures.
The study performs a comparative analysis of the wear of tools made of two wear-resistant materials: steel Hardox 600 and NC11LV, used in the process of forming a band for roofing tiles. The analyses were to allow the assessment of the possibility of replacing the standard material for tools in this process with a much less expensive tool steel for cold work after heat treatment (with a large number of carbides), as an alternative material dedicated to tools resistant to intense abrasive wear. The performed investigations included a macroscopic and geometrical analysis with the use of 3D scanning, microstructural analyses conducted by means of a light microscope, as well as an analysis of the topography of the working areas of the tools with the use of SEM, and microhardness tests. The obtained results demonstrate that the tools made of both materials were characterized with a similar level of wear, which, in the most critical area, reached over 4 mm, while the tools made of steel NC11LV worked over a much longer period of time without regeneration, equaling 912 h, and an insert made of steel Hardox 600 operated for 384 h. A higher tool life in the case of NC11LV steel may be the result of higher hardness and the presence of hard carbides.
The article performs an analysis of a hot die forging process of producing an elongated forging ended with a joggle in a double system realized on a crank press Masey 1300 t, in open dies, in 3 operations. The thermomechanical model of the forging process considering the changes in the grain size and the forging material recrystallization was elaborated with the use of the calculation packet Qform 7. In the first place, an in-depth analysis of the currently realized forging technology was made, with a special consideration of the temperature changes in the tools as well as in the formed forging. Next, numerical modelling of the process was carried out, as a result of which the following were obtained: correct filling of the tool impressions by the deformed material, the temperature distributions for the forging and the tools, the plastic deformation distributions (considering the thermally activated phenomena), the changes in the grain size and the forging force courses. The results obtained from FEM enable a thorough analysis of the forging process, including: the effect of the deformation time and temperature on the grain size in the forging material, which was confirmed by the microstructure examination results.
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