Statistical investigation of die wear in metal extrusion processes

Abstract

The aim of this paper is the statistical process control analysis of the tool wear evolution during metal extrusion process for better understanding the principal causes that generate the variability of such a complex phenomenon. The wear prediction is carried out using finite element simulation including the Archard wear model. The tool wear modeling is presented briefly as well as the response surface methodology. The study is based on the application of the central composites designs and allows for the analysis of the response (wear) sensitivity of the tool. The statistical investigation of the process makes it possible to study the influence of each process parameter on the response sensitivity.

Prediction of abrasive punch wear in copper alloy thin sheet blanking

“…Behrens and Schaefer [6] have used the Archard model with variable hardness to calculate tool wear during hot forging. Lepadatu et al [35] have analysed die wear evolution during the metal extrusion process by means of Archard equation. Ersoy-Nürnberg et al [36] have developed a modified Archard model related on dissipated energy to estimate die wear in deep drawing application.…”

Characteristics of tool wear in a combined double cup extrusion process

“…In 1938, Siebel [14] reviewed the state of the art of the early period of systematic wear research and distinguished between different types of wear such as by sliding, rolling, erosion and cavitations. After World War II, Archard found the empirical rule that the wear volume is directly proportional to the normal load and the sliding distance, and inversely proportional to the hardness of the softer material and this theory has been widely accepted to predict the wear volume by many researchers [15][16][17][18]. The depth of wear was numerically evaluated even in closed hot forging process by adopting a constant wear coefficient by Abachi [19].…”

Tool Wear Monitoring for Ultrasonic Metal Welding of Lithium-Ion Batteries

“…TCM has been a popular and important research topic in manufacturing and has received tremendous attention over the past several decades. The majority of the TCM literature has been focused on machining processes [7][8][9][10][11][12][13][14][15][16][17][18][19][20] and forming processes [21][22][23][24]. Tool wear mechanism in cutting processes has been investigated in Refs.…”

“…Tool wear in forming processes has also been investigated, especially in extrusion and forging processes [21][22][23][24]. Archard's wear model is widely applied in studies on extrusion processes [21,22].…”

“…Statistical process control analysis of the tool wear progression in a metal extrusion process was conducted in Ref. [23]. On the TCM of forging processes, an online TCM system using artificial neural network was developed to integrate information from multiple sensors [24].…”