Review of selected methods of increasing the life of forging tools in hot die forging processes

Hawryluk, Marek

doi:10.1016/j.acme.2016.06.001

Cited by 102 publications

(57 citation statements)

References 23 publications

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“…Selection of base surfaces is of critical significance in the reverse method, and this issue was discussed in works [12,16,18,20]. In the presented analysis of the yoke forging (Fig.…”

Section: Resultsmentioning

confidence: 99%

“…This is why it is justified and significant to conduct tests, particularly with the application of scanning techniques, for the purpose of rapid assessment of actual wear and the current condition of forging tools over the course of their operation without the need to interrupt production or dismount tools from the forging unit. Interpretation of the results of such tests and analyses may help to find ways of optimizing performed die forging processes [9,[15][16].…”

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

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Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Dworzak¹,

Hawryluk²,

Ziemba³

2017

Adv. Sci. Technol. Res. J.

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This article presents a wear analysis of die inserts used in the hot forging process of a forked forging (yoke), an element applied in steering systems of passenger vehicles. Studies involved the application of an original reverse scanning method intended for rapid and reliable wear analysis of forging tools (with complicated shape) affording easy assessment without the need to dismount tools from the forging unit. The developed method involves analysis of progressive wear of forging tools based on measurements (scanning) of forgings periodically collected from the process and constitutes a useful tool for measurement and testing. As the authors' earlier works have demonstrated, the proposed new approach to analysis of tool wear with the application of reverse 3D scanning has proven successful in multiple instances in the case of axially symmetrical objects. The presented results of studies indicate that it is possible to utilize the expanded method to analyze the lifetime of forging tools, including tools with complex geometry. Application of the reverse scanning method allows for continuous and practical monitoring of the condition of forging tools over the course of the forging process and should have a positive impact on improving production output and reducing production costs.

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“…Selection of base surfaces is of critical significance in the reverse method, and this issue was discussed in works [12,16,18,20]. In the presented analysis of the yoke forging (Fig.…”

Section: Resultsmentioning

confidence: 99%

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Dworzak¹,

Hawryluk²,

Ziemba³

2017

Adv. Sci. Technol. Res. J.

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“…Tool durability is a complex issue, and tool wear significantly lowers the quality of the produced forgings. This subjects were widely described by authors in following works [23][24][25]. In the work [24], the author concentrates on selected methods, which provide the highest effectiveness in the improvement of the forging tool life, used in the industrial processes of die forging, based on own research and experiments realized in cooperation with the forging industry.…”

Section: Introductionmentioning

confidence: 99%

“…This subjects were widely described by authors in following works [23][24][25]. In the work [24], the author concentrates on selected methods, which provide the highest effectiveness in the improvement of the forging tool life, used in the industrial processes of die forging, based on own research and experiments realized in cooperation with the forging industry. The most frequent forging defects caused by wear are errors in the filling of the die impression, that is: incomplete forging, laps, burrs, bends, scratches, delaminations, micro-and macro-cracks, etc.…”

Section: Introductionmentioning

confidence: 99%

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Gronostajski¹,

Hawryluk²,

Kaszuba³

et al. 2017

Archives of Metallurgy and Materials

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This study is focused on tools used in the industrial process of hot forging of a front wheel forging (gear wheel) manufactured for the automotive industry. Five different variants were applied for the tools: 3 die inserts were coated with three different hybrid layers (PN + PVD type), i.e. AlCrTiN, AlCrTiSiN and CrN, one insert was only nitrided, and one was pad welded, to improve tool durability. The tool wear was analysed and represented by the material degradation on the working surface, based on the 3D scanning and the material growth of the periodically collected forgings. Additionally, the scanned tools were divided into two areas, in which it was found, based on the analysis, that various degradation mechanisms are predominant. Microstructural tests and hardness measurements of the analyzed tools were also performed. Based on the results, it was found that, in the central part of the die insert, thermo-mechanical fatigue, abrasive wear and plastic deformation occurred, while in the area of the bridge insert, only abrasive wear could be observed. For these areas, the loss of material was determined separately. It was established that the use of the GN+CrN and GN+AlCrTiN hybrid layers on forging tools improves their durability, while the best results in the central area were observed on the tool with the GN+CrN layer, which is the most resistant to thermo-mechanical fatigue. In the second analyzed area, good wear resistance occurred on GN+CrN, GN+AlCrTiN and pad welded inserts, for which, together with the increase of the forging number, a proportional, slight growth of the loss of material occurred.

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“…A little different case is with forging tools which are not lubricated or cooled, for which the typical degradation mechanism is abrasive wear and plastic deformation [3][4][5]7,10]. The research performed by the authors concerning the analysis of the surface layer of forging tools showed that, in the case of forging processes conducted at elevated temperatures, for typical tool work conditions (lubrication and cooling), the percentage of abrasive wear as the dominant degradation mechanism decreases [11][12], and the participation of thermo-mechanical fatigue significantly increases, this process being the one which accelerates the visible and easily measured abrasive wear, as a result of which the tools are removed from production [13][14].…”

Section: Introductionmentioning

confidence: 99%

Factors Affecting the Wear Resistance of Forging Tools

Zwierzchowski

2017

Archives of Metallurgy and Materials

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The durability of forging tools is a function of many variables: tool heat treatment, surface quality, temperature, pressure, number of forgings, diffusion layers (nitriding) and many others. The objective of study was to analyze and compare the working conditions of forging tools. For the analysis of selected flat surfaces of tools. Analyzed forging dies subjected to normal use. Presented results of laboratory tests . The effect of temperature and time on the properties of the surface layer of forging tools. The results were compared with the literature data. This article shows the results of microhardness tests for forging dies which have forged the corresponding number of forgings. The results of laboratory studies on microhardness of hot working steel 1.2344 in the furnace at various temperatures and time are also presented. The working conditions of the forging tools are very complex. The most often described in the literature are: thermal fatigue, abrasive wear, mechanical fatigue and cracks. The article discusses the effects of increased temperature on the surface properties of forging tools. Forging dies were made of hot work tool steel 1.2344. FEM modeling of changes in the surface layer should take into account changes in tool hardness as a function of time (number of forgings).

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Review of selected methods of increasing the life of forging tools in hot die forging processes

Cited by 102 publications

References 23 publications

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Factors Affecting the Wear Resistance of Forging Tools

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