Selected effective methods of increasing the durability of forging tools in hot forging processes

Gronostajski, Z.; Hawryluk, Marek; Widomski, Paweł; Kaszuba, M.; Nowak, B.; Polak, S.; Rychlik, Marcin; Ziemba, Jacek; Zwierzchowski, M.

doi:10.1016/j.promfg.2018.12.054

Cited by 11 publications

(4 citation statements)

References 9 publications

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“…Currently, cooling lubricants are applied by spray units to reduce the thermal load on the die. However, spray cooling is limited to be used in between forming operations only [1]. Here, additional internal die cooling, by means of conformal internal cooling channels, can reduce the thermal load throughout the forming process.…”

Section: Introductionmentioning

confidence: 99%

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

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Internal die cooling during forging can reduce thermal loads, counteracting surface softening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel’s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.

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Section: Introductionmentioning

confidence: 99%

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

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show abstract

“…This study was beneficial to the accurate prediction of die wear and the optimal design of die geometry in hot-forging process. Gronostajski 9 noted that the use of PVD (Physical Vapor Deposition) hybrid layers, a special solution and the original lubrication system can increase the durability of forging tools in hot-forging processes. Gronostajski 10 found that the factor that most adversely affects the forging process is thermomechanical fatigue, which results in fine cracks that quickly develop into a network of cracks extending over the entire die/forged material contact surface.…”

Section: Introductionmentioning

confidence: 99%

Forming analysis and process study for a 6082 aluminum alloy automobile control arm in the process of forging

Wang

Chai

Tian

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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To reduce the weight of vehicles and save on fuel consumption, the forming analysis and process study for a 6082 aluminum alloy automobile control arm were conducted, and the results are reported here. First, the parameters of the constitutive equation of the 6082 aluminum alloy are determined, and the forming process and the dies of the stretch rolling, bending, and die-forging are proposed and discussed according to the given contours of the control arm. Then, the control arm is simulated by means of Deform-3D, the experiment results of the automobile control arm are compared with the simulation results, and the tensile strength, yield strength, and elongation of the test bars obtained from the control arm can meet the mechanical performance requirements based on the tensile test rig. Finally, the relationship of the die load, die wear, workpiece damage, and workpiece equivalent stress with different processing parameters are analyzed, and the effects of different solid solution times on the strength of control arm are discussed. The results show that when the friction coefficient is 0.3, the die temperature is 250°C, the forging velocity is 230 mm/s, the strain rate is 1s−1 and the solid solution time is 30 min, the die load, die wear, workpiece damage, workpiece equivalent stress, and the mechanical strength are then in a good state. The results of this research provide a reliable basis and analysis method for the forging of aluminum alloy automobile control arms.

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“…This is one of the major factors influencing the market prices of the fixtures. For flashless forging, it is required to use forging tools with superior strength in comparison to their traditional forging analogs [ 1 , 2 , 3 ]. During flashless forging, there may be difficulties filling the forging impression, for example the narrow ribs or sharp corners, which may then lead to excessive loading and cracking of the material [ 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

New Copper Alloys Used to Make Products Intended for Contact with Drinking Water

et al. 2021

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This article presents the results of tests conducted as part of a research project with the primary objective of developing new copper alloys with limited lead content. The new group of materials were created in a production plant. As part of tests, a group of 22 alloys were selected for testing in castability, structural characteristics and hardness. Based on the test results obtained, the group of alloys under study was narrowed down to nine. The mechanical properties of these alloys were determined in static tensile tests as well as in uniaxial upsetting tests at elevated temperature, on the basis of which the group of alloys under investigation was further narrowed to three. Further studies involved technological verification of the application of these alloys under industrial conditions. These alloys were subject to numerical forging analyses, along with forging tests, under semi-industrial conditions, where the degree of filling of a die impression at a specific temperature was measured using an optic scanner. The quality of production of the obtained forgings was evaluated macroscopically with simultaneous observations of the microstructure.

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Selected effective methods of increasing the durability of forging tools in hot forging processes

Cited by 11 publications

References 9 publications

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Forming analysis and process study for a 6082 aluminum alloy automobile control arm in the process of forging

New Copper Alloys Used to Make Products Intended for Contact with Drinking Water

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