A review of the degradation mechanisms of the hot forging tools

Gronostajski, Z.; Kaszuba, M.; Hawryluk, Marek; Zwierzchowski, M.

doi:10.1016/j.acme.2014.07.002

Cited by 87 publications

(55 citation statements)

References 22 publications

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“…This technology makes it possible to provide the surface with the appropriate performance properties and to create a barrier which will effectively limit the influence of the destructive factors [18]. This subject was also tested by authors in previous works [19], where they have found the advantage of using hybrid layers. Hybrid layers were successfully applied in bulk metal forming [20], diecasting [21] and hot forging [22].…”

Section: Introductionmentioning

confidence: 95%

“…For example, a comprehensive analysis of the major destructive mechanisms of tools in the forging process of car steering was presented in work [11]. In order to avoid those phenomena, various methods are used, which usually consist in producing or applying appropriate protective layers, the task of which is the protection from one or more destructive mechanisms [2,12].…”

Section: Introductionmentioning

confidence: 99%

“…That is why they are exposed to the operation of many destructive factors, which cause their wear. The areas especially exposed are the working surface and the surface layer of the tool, and so, most of the mentioned destructive mechanisms refer to these tool areas [2]. The most commonly occurring (also the been tested) destructive mechanisms are: plastic deformation and abrasive wear in warm forging [3] and hot forging processes [4], thermal fatigue cracking [5][6][7] and thermo-mechanical fatigue [8].…”

Section: Introductionmentioning

confidence: 99%

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The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Gronostajski¹,

Hawryluk²,

Kaszuba³

et al. 2017

Archives of Metallurgy and Materials

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This study is focused on tools used in the industrial process of hot forging of a front wheel forging (gear wheel) manufactured for the automotive industry. Five different variants were applied for the tools: 3 die inserts were coated with three different hybrid layers (PN + PVD type), i.e. AlCrTiN, AlCrTiSiN and CrN, one insert was only nitrided, and one was pad welded, to improve tool durability. The tool wear was analysed and represented by the material degradation on the working surface, based on the 3D scanning and the material growth of the periodically collected forgings. Additionally, the scanned tools were divided into two areas, in which it was found, based on the analysis, that various degradation mechanisms are predominant. Microstructural tests and hardness measurements of the analyzed tools were also performed. Based on the results, it was found that, in the central part of the die insert, thermo-mechanical fatigue, abrasive wear and plastic deformation occurred, while in the area of the bridge insert, only abrasive wear could be observed. For these areas, the loss of material was determined separately. It was established that the use of the GN+CrN and GN+AlCrTiN hybrid layers on forging tools improves their durability, while the best results in the central area were observed on the tool with the GN+CrN layer, which is the most resistant to thermo-mechanical fatigue. In the second analyzed area, good wear resistance occurred on GN+CrN, GN+AlCrTiN and pad welded inserts, for which, together with the increase of the forging number, a proportional, slight growth of the loss of material occurred.

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Section: Introductionmentioning

confidence: 95%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Gronostajski¹,

Hawryluk²,

Kaszuba³

et al. 2017

Archives of Metallurgy and Materials

Self Cite

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show abstract

“…Forging die inserts used in the industrial hot forging processes characterize in a relatively low hardness, which directly translates to both the quality and the cost of the forging production. To a lesser extent, the tool's resistance to degradation mechanisms depends on its construction (shape of the working surface), the tool material and its appropriate thermal treatment as well as surface layer treatment; the least influence is exerted by the shape of the preform [6,7].…”

Section: Introductionmentioning

confidence: 99%

“…This makes the operation conditions for non-lubricated, and thus non-cooled, tools to be different from the ones for lubricated tools. A little different case is with forging tools which are not lubricated or cooled, for which the typical degradation mechanism is abrasive wear and plastic deformation [3][4][5]7,10]. The research performed by the authors concerning the analysis of the surface layer of forging tools showed that, in the case of forging processes conducted at elevated temperatures, for typical tool work conditions (lubrication and cooling), the percentage of abrasive wear as the dominant degradation mechanism decreases [11][12], and the participation of thermo-mechanical fatigue significantly increases, this process being the one which accelerates the visible and easily measured abrasive wear, as a result of which the tools are removed from production [13][14].…”

Section: Introductionmentioning

confidence: 99%

Factors Affecting the Wear Resistance of Forging Tools

Zwierzchowski

2017

Archives of Metallurgy and Materials

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The durability of forging tools is a function of many variables: tool heat treatment, surface quality, temperature, pressure, number of forgings, diffusion layers (nitriding) and many others. The objective of study was to analyze and compare the working conditions of forging tools. For the analysis of selected flat surfaces of tools. Analyzed forging dies subjected to normal use. Presented results of laboratory tests . The effect of temperature and time on the properties of the surface layer of forging tools. The results were compared with the literature data. This article shows the results of microhardness tests for forging dies which have forged the corresponding number of forgings. The results of laboratory studies on microhardness of hot working steel 1.2344 in the furnace at various temperatures and time are also presented. The working conditions of the forging tools are very complex. The most often described in the literature are: thermal fatigue, abrasive wear, mechanical fatigue and cracks. The article discusses the effects of increased temperature on the surface properties of forging tools. Forging dies were made of hot work tool steel 1.2344. FEM modeling of changes in the surface layer should take into account changes in tool hardness as a function of time (number of forgings).

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A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

Sharma

Gupta

et al. 2023

steel research int.

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Forging is a primary manufacturing process used in several manufacturing industries. Aircraft and automobile industries are manufacturing products with high‐dimensional accuracy and quality that are highly precise or near the required shape. Customers require products that are free of cracks and fulfill their functional requirements. This leads to the advancement of the forging process due to its ability to form complicated and intricate shapes. Herein, a detailed review of the aspects of forging is given in which the optimization of factors like preform design, forging conditions, workpiece dimensions, die design, lubricant properties, and thermal treatment parameters are discussed, enhancing the tool life and forging quality of the product. The selection of die‐forging tool material and methods for enhancing the surface quality of forged products are also reviewed. The article also presents methods for measurement of forging quality, tool life, machine effectiveness, forging image acquisition, and forging parameters, which can significantly reduce the risk of error at every step of the forging process. This review serves as a reference for researchers to increase production rate, enhance the effectiveness of measurement system, and improve the quality of forged products with technological advancement.

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A review of the degradation mechanisms of the hot forging tools

Cited by 87 publications

References 22 publications

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Factors Affecting the Wear Resistance of Forging Tools

A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

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