Hot shearing processes: Correlation of numerical simulation with real wear phenomena

Torres, Héctor; Horwatitsch, Dieter; Varga, M.; Schuster, Miriam; Adam, Karl; Ripoll, Manel Rodríguez

doi:10.1016/j.triboint.2014.01.025

Cited by 11 publications

(4 citation statements)

References 30 publications

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“…14: finite elements located in the upper part of burnish zone (elements nos. [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19] have been subjected to shear failure mode, and lower part (elements nos. 20-30) have been generated following a combination of shear and void growth failure modes.…”

Section: Stress Triaxiality Distributionmentioning

confidence: 99%

“…Behrens and Schaefer [6] have performed hot forging process simulation by means of finite element modelling to predict tool wear. More recently, Torres et al [7] have used FEM to simulate hot metal shearing process and have found good correlation between stress distributions within the tool and wear location observed on tool real shape. However, tool wear prediction has been less investigated in blanking process.…”

Section: Introductionmentioning

confidence: 99%

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Prediction of abrasive punch wear in copper alloy thin sheet blanking

Falconnet

Chambert

Makich

et al. 2015

Wear

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a b s t r a c tThis work presents a combination of finite element simulations of copper alloy thin sheet blanking and a wear algorithm based on Archard formulation for abrasive wear of the punch. Firstly, a tribometer has been specifically designed to measure wear coefficient, and punch worn profiles have been extracted by means of a double-print method. Secondly, the blanking process has been simulated through the finite element method by using an elasto-plastic constitutive model and the shear failure model. Thirdly, a wear algorithm has been programmed using experimental wear data and mechanical fields computed from blanking simulation. Then, a damage criterion, namely the shear failure model, has been calibrated by an original method based on stress triaxiality analysis and shear height value measured from blanked edge profile. Finally, punch wear predictions have been discussed and compared to experimental results.

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Section: Stress Triaxiality Distributionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Prediction of abrasive punch wear in copper alloy thin sheet blanking

Falconnet

Chambert

Makich

et al. 2015

Wear

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show abstract

“…The analytical, numerical and experimental methods has been combined to investigate the wear and predict service life for a variety of pressure forming process. For aspects of the mould wear studying, Torres et al [6] used FEM to simulate hot metal shearing process and found a good correlation between the stress distributions on the tool and wear location observed on tool shape. Luo et al [7] investigated the wear characteristics of the die in a process of the hot forging turbine blade, the influences of the temperature on the wear evolution and distribution were discussed.…”

Section: Introductionmentioning

confidence: 99%

Investigating Wear and Predicting Lifetime of the Roller Cavities for the Net-shape Blade Rolling

Jin¹,

Wang²,

Jiang³

et al. 2021

Preprint

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The die undergoing severe loads which induces inevitably wear in the pressure forming process, and the wear of die arouses obsessions about the die’s service lifetime. In order to obtain the geometrical shape transformation caused by wear and predict the service lifetime for a pair of rollers in net-shape blade rolling process, this paper quantified the distributions and evolutions of the local wear over roller cavities based on the local contact load responses, and predicted the lifetime which related to wear by a mathematical models. Firstly, the net-shape blade rolling process and the local contact load responses were summarized. Then, an improved wear model was provided based on the Archard formula, and the impact factors of the model was standardized by a regression analysis experiment. The transient wear distributions and evolutions over the roller cavities were enumerated, and the wear distribution for one rolling cycle was calculated based on wear accumulation effect. Finally, a lifetime prediction model was proposed to predict the service lifetime of the rollers according to the wear accumulation effect, and an experimental verification was carried out to validate the model. The results showed that the wear model and lifetime prediction model can be used for investigating the wear and lifetime prediction of the roller cavities for the net-shape blade rolling process.

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“…In particular, metal forming processes like hot rolling or hot stamping involve the heating of the work piece to prevent the onset of detrimental mechanisms such as strain hardening and also to increase the ductility of the work piece at HT [6]. However, such an approach can lead to significant tool damage due to increased wear and material transfer from the work piece [7][8][9][10][11], thus decreasing tool lifetime and compromising the quality of the finished product. Materials like ceramics are in general not suited to replace metallic alloys under these conditions owing to their poor mechanical integrity as well as their tribological properties at elevated temperatures [12,13].…”

Section: Introductionmentioning

confidence: 99%

Tribological behaviour of self-lubricating materials at high temperatures

Torres

Ripoll

Prakash

2017

International Materials Reviews

190

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Self-lubricating materials are becoming more widespread in fields like metal forming or power generation due to the inability to use conventional lubricants in high-temperature (HT) applications. In an effort to summarise the progress done in this field, a detailed literature review has been carried out, ranging from micron-thickness thin films to hardfacings and bulk materials, and classified by the reported solid lubricants. Moreover, the most-cited deposition techniques have been reviewed for each lubricant class in addition to their advantages and limitations. HT friction and wear data for self-lubricating materials have also been examined in order to identify effective lubrication ranges and general trends in their tribological behaviour, which is expected to be useful for researchers interested in this field. Finally, several apparent research gaps have been described, with suggestions for new experimental work that could lead to the development of new high-temperature selflubricating materials.

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Hot shearing processes: Correlation of numerical simulation with real wear phenomena

Cited by 11 publications

References 30 publications

Prediction of abrasive punch wear in copper alloy thin sheet blanking

Prediction of abrasive punch wear in copper alloy thin sheet blanking

Investigating Wear and Predicting Lifetime of the Roller Cavities for the Net-shape Blade Rolling

Tribological behaviour of self-lubricating materials at high temperatures

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