Net shape cold forging to close tolerances under QS 9000 aspects

Meidert, M.; Hänsel, Matthias

doi:10.1016/s0924-0136(99)00191-0

Cited by 6 publications

(4 citation statements)

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“…By adding this parameter to the acceptable wear depth and the node threshold, a more easily comprehensible wear volume can be calculated to determine the end of tool life. Following the argumentation of Jafors et al [ 25 ], the tool life of a single die must always be considered as a single data point which is subject to strong fluctuations in the industrial manufacturing process [ 28 ]. Against this background, the calculated tool life represents a statistical mean value which can only be compared to a statistical evaluation of the lifetime over a longer period of time.…”

Section: Discussionmentioning

confidence: 99%

“…Whereas for the material characterization of the base material within the scope of this study, a very detailed modeling could be referenced, a single static hardness value in connection with a constant layer thickness was defined as a first approach for the properties of the nitrided protection layer. As the properties of this layer in terms of hardness during the adjustment process are essentially determined by the set temperatures and treatment times [ 17 , 28 ], it can be assumed that the properties of this layer also undergo an evolution during the ongoing process. For this reason, a characterization analogous to the one described by Müller et al [ 19 ] is already in progress in order to implement the results in the next iteration into the model described here.…”

Section: Future Workmentioning

confidence: 99%

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Multi-Layer Wear and Tool Life Calculation for Forging Applications Considering Dynamical Hardness Modeling and Nitrided Layer Degradation

et al. 2020

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As one of the oldest shaping manufacturing processes, forging and especially hot forging is characterized by extreme loads on the tool. The thermal load in particular is able to cause constant changes in the hardness of the surface layer, which in turn has a decisive influence on the numerical estimation of wear. Thus, also during numerical wear, modeling hardness changes need to be taken into account. Within the scope of this paper, a new implementation of a numerical wear model is presented, which, in addition to dynamic hardness models for the base material, can also take into account the properties of a nitride wear protection layer as a function of the wear depth. After a functional representation, the new model is applied to the wear calculation of a multi-stage industrial hot forging process. The applicability of the new implementation is validated by the evaluation of the occurring hardness, wear depths and the locally associated removal of the wear protection layer. Consecutively, a tool life calculation module based on the calculated wear depth is implemented and demonstrated. In general, a good agreement of the results is achieved, making the model suitable for detailed 2D as well as large 3D Finite Element calculations.

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Section: Discussionmentioning

confidence: 99%

Section: Future Workmentioning

confidence: 99%

Multi-Layer Wear and Tool Life Calculation for Forging Applications Considering Dynamical Hardness Modeling and Nitrided Layer Degradation

et al. 2020

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“…Meidert and Hansel [5] studied the tool lifespan for typical net shape cold forging parts produced for the automotive industry (see Figure 1a). It should here be noted that the failure mode in this study was primarily fatigue failure or over load and rarely wear failure.…”

Section: Observed Tooling Life Span Variation and Failurementioning

confidence: 99%

“…Tool life, (a) data of life spans of individual tool inserts over time illustrating the large variation observed under industrial practice conditions, after ref. [5]; (b) schematic relation between toll hardness and reasons for failure in tooling after ref. [6].…”

Section: Observed Tooling Life Span Variation and Failurementioning

confidence: 99%

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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Finite element modelling and simulation of bulk material forming

Mackerle

2006

Engineering Computations

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Purpose -To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up-to-date. Design/methodology/approach -A range of published (1996)(1997)(1998)(1999)(2000)(2001)(2002)(2003)(2004)(2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies. Findings -Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject. Research limitations/implications -It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included. Practical implications -A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field. Originality/value -There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.

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Net shape cold forging to close tolerances under QS 9000 aspects

Cited by 6 publications

References 0 publications

Multi-Layer Wear and Tool Life Calculation for Forging Applications Considering Dynamical Hardness Modeling and Nitrided Layer Degradation

Multi-Layer Wear and Tool Life Calculation for Forging Applications Considering Dynamical Hardness Modeling and Nitrided Layer Degradation

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

Finite element modelling and simulation of bulk material forming

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