Influence of the fabrication method on the wear resistance of hot forging dies

Behrens, Bernd‐Arno; Yilkiran, Timur

doi:10.1007/s11740-012-0373-y

Cited by 11 publications

(5 citation statements)

References 5 publications

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“…The materials used in this work are AISI H13 steel for the disks, AISI 1045 for the tool pins, and graphite diluted in water as a lubricant because it is the most common combination used in the hot forging process [13]. A Promecor SMT 19/500 numerical control lathe (Promecor, Córdoba, Argentina) was used to machine 8 AISI H13 steel disks with an external diameter of 60 mm, an internal diameter of 19 mm, and 6.5 mm of thickness.…”

Section: Methodsmentioning

confidence: 99%

“…Half of the roughing WEDM disks were polished for 1 minute with an abrasive paper of SiC of a mesh size 60 (equivalent to 250 μm) until reaching an average surface roughness (R a ) of approximately 5 μm. This range of values for R a is common in forging dies [13]. These polishing processes were carried out using a belt sander, applying a normal load on the sample of 15 N similar to [21].…”

Section: Methodsmentioning

confidence: 99%

“…There are two routes to manufacturing hot forging dies of AISI H13: high-speed milling or electrical discharge machining (EDM). In both cases, the finishing is done by polishing [5][6][7][8][9][10][11][12][13][14][15].…”

Section: Introductionmentioning

confidence: 99%

“…Pellicer et al [12] also focused on evaluating the influence of the shape of the electrode and different EDM process variables on the surface finishing. Although EDM leaves a good surface roughness, subsequent polishing is necessary to eliminate the causes of surface defects [13]. Polishing is habitually done with abrasive material, and the polishing time can be estimated mainly as a function of the hardness of the material to be polished, its surface roughness, and the grain size of the abrasive used during the process [14].…”

Section: Introductionmentioning

confidence: 99%

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Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

Egea

Martynenko

Simoncelli

et al. 2021

Int J Adv Manuf Technol

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Forging dies are crucial in forging to manufacture accurate workpieces. These dies are generally made of AISI H steel series and hardened and tempered medium carbon alloy steel. Dies are processed by using high-speed milling + polishing or electrical discharge machining + polishing. The surface quality of the workpiece depends on the surface properties of these dies, where surface roughness, material hardness, and wear evolution of their surfaces are critical aspects to consider. This research analyzes different wire electrical discharge machining surface conditions combined with polishing treatment to describe their influence on friction and wear. Wire electrical discharge machining defines the disks’ surface properties in finishing and roughing conditions, and polishing treatment varies in time and paper sand depending on the roughness. Abbott-Firestone curves and Rsk-Rku roughness parameters characterize the surface roughness of each studied configuration. Room temperature pin-on-disk tests were performed to analyze friction coefficients and wear rate for AISI 1045 pins and AISI H13 disks. On average, the highest (0.284) and the lowest (0.201) friction coefficients were found for the combination of finishing wire electrical discharge machining + polishing and roughing wire electrical discharge machining conditions, respectively. Scanning electron microscope images were taken to describe the wear tracks and pin degradation for different sliding abrasive configurations. The diagram correlating the surface morphology and the friction coefficient predicts the wear damage on initial surface conditions, which is crucial in the forging industry to determine tool maintenance or replacement.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

Egea

Martynenko

Simoncelli

et al. 2021

Int J Adv Manuf Technol

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“…Moreover, in relation to the surface integrity of the die and the degradation of the coating layer due to advancing wear, Behrens et al [26] developed a method for calculating the die life as a function of the surface hardness of the die. Among the die production methods, EDM has proved to be the most valid for the surface resistance results obtained: thanks to the martensitic microstructure reinforced with extremely hard iron carbides and the lower presence of surface defects compared to cutting processes, it offers excellent resistance to wear; failure, in this case, is due to the underlying layer that softens with repeated high-temperature cycles [27]. In the first phase of use of the die, therefore, it can be assumed that the weakening effect due to thermal cycles is secondary to wear (the latter acts immediately while several cycles are needed before the microstructure is significantly altered).…”

Section: Introductionmentioning

confidence: 99%

Application of design of experiments to forging simulations to increase die life expectancy

Alessio

Antonelli

Doglione

et al. 2022

Int J Interact Des Manuf

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Wear and fracture of steel dies employed in hot forging were evaluated through metallographic study with the aim of qualifying a Finite Element Simulation of the productive process. Apart from providing useful insights into the causes of die damaging, the simulation was exploited in a Design of Experiments to prevent fracture and to counter different mechanisms of wear. The objective is the optimization of die life acting only on process parameters that are directly adjustable in the actual industrial process. In the examination of stress distribution on the dies and the estimation of die wear, the complete forging cycle has been taken into consideration. Despite the considerable variability of the process, the study demonstrates that it is possible to prevent fracture insurgence and to increase the life expectancy of the die by a careful tuning of standard process parameters. Possible stakeholders of the study are not only process designers but also production managers, as most process parameters are modifiable during production.

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Increase of the computational accuracy of hot bulk forming process simulations with improved friction modeling

Bouguecha¹,

Hadifi

Mielke

et al. 2012

Materialwissenschaft Werkst

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Die Ressourceneffizienz von Fertigungsverfahren setzt den genauen Einsatz von Energie und vom Rohteilmaterial voraus. Hierbei spielt insbesondere in der Umformtechnik die gezielte simulationsgestützte Auslegung des Prozesses eine bedeutende Rolle. Ein etabliertes Berechnungsverfahren stellt die Finite‐Element‐Methode (FEM) dar. Mit ihrem Einsatz werden kosten‐ und zeitintensive Trial‐and‐Error‐Versuche reduziert und im besten Fall sogar zuverlässig vermieden. Dabei ist eine realitätsnahe Beschreibung der komplexen Wirkmechanismen in der Interaktion zwischen Werkzeug und Werkstück über eine geeignete Reibmodellierung entscheidend. In diesem Beitrag wird das neu entwickelte IFUM‐Reibmodell und dessen Einsatz bei der FE‐Berechnung komplexer Schmiedeprozesse vorgestellt.

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Influence of the fabrication method on the wear resistance of hot forging dies

Cited by 11 publications

References 5 publications

Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

Application of design of experiments to forging simulations to increase die life expectancy

Increase of the computational accuracy of hot bulk forming process simulations with improved friction modeling

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