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

Dworzak, Ł.; Hawryluk, Marek; Ziemba, Jacek

doi:10.12913/22998624/80318

Cited by 4 publications

(4 citation statements)

References 27 publications

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“…However, [ 31 , 32 ] describe the use of an improved lubricating and cooling system additionally equipped with an automatic system cleaning system. The system was implemented in an industrial forging process of a forked type forging, which resulted in the tool life being extended by approximately 20% [ 33 ]. The analysis of the state of the art indicates that the issues of lubricating and cooling systems and process parameters of lubricant feeding are still valid.…”

Section: Introductionmentioning

confidence: 99%

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

2021

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The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings that ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM (Scanning Electron Microscope). For the best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool up to the maximum service life.

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Section: Introductionmentioning

confidence: 99%

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

2021

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“…By this means, different optical geometry reconstruction methods are used. Several authors have used stereo-vision [ 4 , 5 ], light-section [ 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 ] or fringe projection profilometry [ 16 ] to acquire geometry data for quality control and wear analysis for hot forging processes. In previous papers, we have presented a method to estimate the influence of refractive index gradients on the results of optical 3D geometry measurements of hot specimen by evaluation of the reconstruction quality [ 17 ].…”

Section: Introductionmentioning

confidence: 99%

Adapted Fringe Projection Sequences for Changing Illumination Conditions on the Example of Measuring a Wrought-Hot Object Influenced by Forced Cooling

Quentin

Beermann

Reinke

et al. 2021

Sensors

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Optical 3D geometry reconstruction, or more specific, fringe projection profilometry, is a state-of-the-art technique for the measurement of the shape of objects in confined spaces or under rough environmental conditions, e.g., while inspecting a wrought-hot specimen after a forging operation. While the contact-less method enables the measurement of such an object, the results are influenced by the light deflection effect occurring due to the inhomogeneous refractive index field induced by the hot air around the measurand. However, the developed active compensation methods to fight this issue exhibits a major drawback, namely an additional cooling of the object and a subsequent transient illumination component. In this paper, we investigate the cooling and its effect on temporal phase reconstruction algorithms and take a theoretical approach to its compensation. The simulated compensation measures are transferred to a fringe projection profilometry setup and are evaluated using established and newly developed methods. The results show a significant improvement when measuring specimens under a transient illumination and are easily transferable to any kind of multi-frequency phase-shift measurement.

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“…The accuracy of the method was estimated by comparing the reconstructed the geometry of the cold object with a reference measurement; therefore, neither a single point accuracy nor a hot reference method was given. Hawryluk and Dworzak et al 15,16 used the combination of a light-section laserscanner with a measuring arm, which is a six-axis serial arm reconstructing the 3-D position of its tip by measuring its joint angles. The system was used to reconstruct the geometry of the tools used in a hot-forming process.…”

Section: Introductionmentioning

confidence: 99%

Development of a reconstruction quality metric for optical three-dimensional measurement systems in use for hot-state measurement object

et al. 2020

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Optical three-dimensional (3-D) geometry measurements are state of the art when it comes to contactless quality control and maintenance of the shape of technical components that exclude tactile measurements due to filigree or internal structures. Optical inspection methods are also characterized by a fast and high-resolution 3-D inspection of complex geometries. And due to their noncontact principle, they can carry out measurements in places that would otherwise not be accessible due to harsh environmental conditions or specimens such as hot forged parts. However, there are currently no methods to estimate the reconstruction quality for the optical 3-D geometry measurements of hot objects. The mainly used geometric measurement standards cannot be used for the characterization of hot measurements since the calibrated geometrical values are not transferable to high temperatures. For the development of such a metric, we present the fundamentals of the concepts and algorithms for an estimation of the reconstruction quality are presented and evaluated using a two-dimensional simulation model. The generated findings were applied to the 3-D geometry measurement of a hot object in a laboratory environment. The results are compared with general state-of-the-art reconstruction quality metrics. © The Authors. Published by SPIE under a Creative Commons Attribution 4.0 Unported License. Distribution or reproduction of this work in whole or in part requires full attribution of the original publication, including its DOI.

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

Cited by 4 publications

References 27 publications

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

Adapted Fringe Projection Sequences for Changing Illumination Conditions on the Example of Measuring a Wrought-Hot Object Influenced by Forced Cooling

Development of a reconstruction quality metric for optical three-dimensional measurement systems in use for hot-state measurement object

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