Analysis of the main types of damage on a pair of industrial dies for hot forging car steering mechanisms

Lavtar, Lejla; Muhič, Tadej; Kugler, G.; Terčelj, Milan

doi:10.1016/j.engfailanal.2010.11.002

Cited by 65 publications

(38 citation statements)

References 19 publications

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“…Analysis of wear and lifetime is an exceptionally difficult task. The multitude of factors affecting the correctness of the forging process, and thus tool lifetime, has spurred the application of a series of CAD/CAM/ CAE and FEM tools for analysis and optimization of forging technologies, including for the purposes of extending lifetime [15,26,35]. Currently, an increasing number of scientific research centers, whether at universities, R&D units or industrial plants, are employing a comprehensive approach to lifetime assessment of forging apparatus.…”

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Dworzak¹,

Hawryluk²,

Ziemba³

2017

Adv. Sci. Technol. Res. J.

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This article presents a wear analysis of die inserts used in the hot forging process of a forked forging (yoke), an element applied in steering systems of passenger vehicles. Studies involved the application of an original reverse scanning method intended for rapid and reliable wear analysis of forging tools (with complicated shape) affording easy assessment without the need to dismount tools from the forging unit. The developed method involves analysis of progressive wear of forging tools based on measurements (scanning) of forgings periodically collected from the process and constitutes a useful tool for measurement and testing. As the authors' earlier works have demonstrated, the proposed new approach to analysis of tool wear with the application of reverse 3D scanning has proven successful in multiple instances in the case of axially symmetrical objects. The presented results of studies indicate that it is possible to utilize the expanded method to analyze the lifetime of forging tools, including tools with complex geometry. Application of the reverse scanning method allows for continuous and practical monitoring of the condition of forging tools over the course of the forging process and should have a positive impact on improving production output and reducing production costs.

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Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Dworzak¹,

Hawryluk²,

Ziemba³

2017

Adv. Sci. Technol. Res. J.

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“…Jak się szacuje, koszty narzędzi mogą obecnie stanowić nawet 8÷15% całkowitych kosztów produkcji. Jeśli zaś uwzględni się czas potrzebny na wymianę zużytego oprzyrządowania oraz przypadki nieoczekiwanego zniszczenia narzędzi, koszty te mogą wzrosnąć nawet do 30÷50% [1,2].…”

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Modeling of wear rate in hot forming dies

2015

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Modelowanie numeryczne procesu zużycia ściernego matryc do kucia na gorąco Actual wear rate occurring to the gear wheel hot forging die inserts as determined by experiment is compared with that resulting from mathematical modeling (FEM) to the Archard's abrasive wear model. In order to determine real wear rate, working faces of the forging die inserts were inspected before and after 4300 forging cycles.

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“…Among them, the most extensively studied one is the mechanism of wear is abrasive wear, which prevails also in the process for cold forging [9,10]. 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%

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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Analysis of the main types of damage on a pair of industrial dies for hot forging car steering mechanisms

Cited by 65 publications

References 19 publications

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Modeling of wear rate in hot forming dies

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

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