Increasing tool life in cold forging through advanced design and tool manufacturing techniques

Lange, Kurt; Hettig, Arndt; Knoerr, Markus

doi:10.1016/0924-0136(92)90337-r

Cited by 41 publications

(14 citation statements)

References 2 publications

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“…Much effort has gone into making three-dimensional process simulation practical, realistic and easy [16,17]. Process simulation models are now routinely and successfully used in a wide range of applications, including material flow, heat-transfer, heat treatment simulation, die stress, deflection, and machining [18].…”

Section: Introductionmentioning

confidence: 99%

Design and analysis of direct cold drawing of section rods through a single die

Wang

Argyropoulos

2005

Journal of Materials Processing Technology

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Section: Introductionmentioning

confidence: 99%

Design and analysis of direct cold drawing of section rods through a single die

Wang

Argyropoulos

2005

Journal of Materials Processing Technology

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“…Lange and coworkers [3] studied cold forward extrusion and identified for this type of die that the failure modes were predominantly of three different kinds, namely overloading, fatigue failure and wear, as illustrated in Figure 3. They concluded that reducing the stress level in cold-forging tooling by modifications in the design has the greatest influence on tool life.…”

Section: Observed Tooling Life Span Variation and Failurementioning

confidence: 99%

“…In order to be able to reduce stress at critical points in the die and to ensure that the material response is appropriate it is thus necessary to address the following points [3]:…”

Section: Observed Tooling Life Span Variation and Failurementioning

confidence: 99%

“…Currently overstressing in tooling can be estimated and reasonably well predicted using finite element modelling (FEM) including elastic defoemation with deviation of product shape [1], but life-span prediction for fatigue and wear with high tool hardness, as required in microforming, is a relatively new area needing further study [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

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Tool Wear and Life Span Variations in Cold Forming Operations and Their Implications in Microforming

et al. 2016

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Abstract:The current paper aims to review tooling life span, failure modes and models in cold microforming processes. As there is nearly no information available on tool-life for microforming the starting point was conventional cold forming. In cold forming common failures are (1) over stressing of the tool; (2) abrasive wear; (3) galling or adhesive wear, and (4) fatigue failure. The large variation in tool life observed in production and how to predict this was reviewed as this is important to the viability of microforming based on that the tooling cost takes a higher portion of the part cost. Anisotropic properties of the tool materials affect tool life span and depend on both the as-received and in-service conditions. It was concluded that preconditioning of the tool surface, and coating are important to control wear and fatigue. Properly managed, the detrimental effects from surface particles can be reduced. Under high stress low-cycle fatigue conditions, fatigue failure form internal microstructures and inclusions are common. To improve abrasive wear resistance larger carbides are commonly the solution which will have a negative impact on tooling life as these tend to be the root cause of fatigue failures. This has significant impact on cold microforming.

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“…Therefore, it can save massive time in preprocess schedule to further upgrade the design level of dies. Lange et al [5] applies various computeraid simulation analyses (NASTRAN, ANSYS, DEFORM, ABAQUS, I-DEAS) to analyze the stress distribution on cold-forging die to predict the damage positions of the die, as well as conducted experiments to investigate the impact of the die curve fillet dimension and incline angle, surface treatment used and the hardness of various materials and thermal treatment on the service life of die. Nagao et al [6] use the finite element software DEFORM to analyze the car forging parts and compare the optimal designed stress ring of die, to understand the pressure phenomenon forced on die, in order to increase the service life of die.…”

Section: Introductionmentioning

confidence: 99%

Multi-stage forging on torx-pin screw with high torque

2017

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Abstract. The study assumes constant shear friction to simulate multi-stage forging on torx-pin screw with high torque using FEM commercial software. Because the screw head has a plum needle shape with the effect of high torque, the 3D simulation model is used to explore the effective stress, the effective strain, the velocity field, and the forging force in each stage. The forming pass schedule considers three stages to obtain the product, and uses the Deform-3D software to explore the feasibility of forming pass schedule. Finally, the realistic manufacturing of torx-pin screw can be carried out to compare with the simulation results to verify the acceptance of FEM simulation. The maximum dimension error between simulation and experiment is around 2.45%, thus the feasibility of FEM simulation to die design for manufacturing the torx-pin screw can be verified.

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Increasing tool life in cold forging through advanced design and tool manufacturing techniques

Cited by 41 publications

References 2 publications

Design and analysis of direct cold drawing of section rods through a single die

Design and analysis of direct cold drawing of section rods through a single die

Tool Wear and Life Span Variations in Cold Forming Operations and Their Implications in Microforming

Multi-stage forging on torx-pin screw with high torque

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