Failure analysis of forging die insert protected with diffusion layer and PVD coating

Podgrajšek, Martin; Glodež, Srečko; Ren, Zoran

doi:10.1016/j.surfcoat.2015.06.021

Cited by 37 publications

(18 citation statements)

References 12 publications

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“…Considering different manufacturing methods combined with different surface conditions, the duplex treated dies show lower geometry deviations than the tempered ones. This confirms the increased wear resistance as reported in the literature [5,8,24,27]. The micro hardness measurements substantiate the assumption that the die material of the tempered dies loses hardness due to thermal influence during forging, encouraging material removal caused by abrasion.…”

Section: Discussionsupporting

confidence: 90%

“…Parts produced in hot forging operations are superior concerning their mechanical properties and thus often used in security-relevant applications. Forging technology represents a cost efficient production method for mechanically highly loaded components in high quantities [1,2]. Due to competitive pressure, forging companies are forced to improve their forming processes continuously.…”

Section: Forging Process and Wear Mechanismsmentioning

confidence: 99%

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Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

et al. 2016

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Tools used in hot forging operations are subjected to high wear during processing due to complex load conditions with high temperatures and mechanical loads. The resulting abridged service lifetime of the dies highly restricts the cost-effectiveness of the production process. Several investigations indicate that the condition of the tool topography during several forging cycles affects the formation of wear distinctly. Thus, an enhancement of the topography in order to reduce tribologically caused wear is expected to increase wear resistance. Within this investigation an appropriate surface structure of forging dies is to be defined. For this purpose, efficient production methods like turning, milling and blasting are applied to generate distinguished die surfaces concerning topographical structures. By investigating the worn-out surfaces, the optimal surface structure can be determined, taking into account topography parameters deduced from the Abbott-Firestone graph. A mechanical stabilization of the created topography is necessary due to the high mechanical and thermal loads during hot forging leading to distinctive topography alterations. Thus, plasma duplex treatments were carried out, consisting of plasma nitriding and hard coatings produced by PECVD coating technique. It can be shown, that the created topography of the forging dies is sustainable over high amounts of forging cycles and thus leads to a reduction of wear.

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Section: Discussionsupporting

confidence: 90%

Section: Forging Process and Wear Mechanismsmentioning

confidence: 99%

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

et al. 2016

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“…Generally, 5CrNiMo or H13 hot forging die are fabricated by hammer forging, mechanical shaping, and surface strengthening [1,2]. Surface strengthening technologies such as carbonitriding [3], thermal desorption spectroscopy (TDS) [4], physical vapor deposition (PVD) [5], chemical vapor deposition (CVD) [6], and plasma-assisted chemical vapor deposition (PACVD) [7] have been applied to medium-sized and small dies and achieved great results. Surfacing is realized by exerting heat sources or melt metal onto the surface of base metal [8].…”

Section: A N U S C R I P Tmentioning

confidence: 99%

Study on the combination of cobalt-based superalloy and ferrous alloys by bimetal-layer surfacing technology in refabrication of large hot forging dies

Shen

Zhou

Xiong

et al. 2017

Journal of Alloys and Compounds

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“…Hence, thoroughly analysing the wear of forging tools and predicting their life is a very important issue and a huge challenge for technologists, tool designers, process engineers and forging companies, as well as many research centres [9,10]. Numerous studies described in the technical literature are devoted, on the one hand, to research works which make it possible to increase the tool life by various techniques of surface engineering [11][12][13][14][15][16] and, on the other, to improvements of the technical and technological process parameters [17], optimization of the tool shape [18], conversion of the tool material to a material more resistant to the effect of destructive mechanisms [19,20], or implementation of proper heat treatment [21].…”

Section: Introductionmentioning

confidence: 99%

Sensitivity analysis of the artificial neural networks in a system for durability prediction of forging tools to forgings made of C45 steel

Mrzygłód

Hawryluk

Janik

et al. 2020

Int J Adv Manuf Technol

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The article presents the results of a sensitivity analysis of artificial neural networks developed for a system which predicts the durability of forging tools used in the selected hot die forging process. The developed system makes it possible to calculate the geometric loss of the examined tool for the given values of its operating parameters (number of forgings, tool temperature at selected points, type of the applied protective layer, pressure and path of friction) and estimates the intensity of the occurrence of typical mechanisms of tool destruction, i.e. thermo-mechanical fatigue, mechanical wear, abrasive wear and plastic deformation. Nine neural networks operate in the developed system. Five of them determine the geometric loss of the material used for tools operating with protective layers, including a nitrided layer, a pad welded layer and three hybrid layers, i.e. AlCrTiSiN, Cr/CrN and Cr/AlCrTiN. Four networks make calculations determining the intensity of the occurrence of typical destructive mechanisms. The developed sensitivity analysis allows for each neural network to show which input parameters are most important and have the greatest impact on the explained variables. This is determined based on the network error analysis in the case of elimination of individual variables from the input data. The greater the network error calculated after rejecting an input variable relative to the error obtained for the network with all the input variables, the more sensitive the network to the lack of this variable. The best compliance was obtained for the first developed set of networks regarding the geometric loss of material, while the lowest compliance was obtained for the second developed set of networks regarding the applied protective layers, and in particular for plastic deformation and mechanical fatigue, probably due to the smallest size of these sets in the knowledge base. The obtained results of this analysis are important for the system operation, i.e. supporting the technologist's decision in the selection of such process parameter values that will increase the die's lifetime.

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Failure analysis of forging die insert protected with diffusion layer and PVD coating

Cited by 37 publications

References 12 publications

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

Study on the combination of cobalt-based superalloy and ferrous alloys by bimetal-layer surfacing technology in refabrication of large hot forging dies

Sensitivity analysis of the artificial neural networks in a system for durability prediction of forging tools to forgings made of C45 steel

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