Analysis of tool heating in cold forging using thin-film sensors

Analysis of tool heating in cold forging using thin-film sensors


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Abstract. Data acquisition and data analysis to gain a better process understanding are one of the most promising trends in manufacturing technology. Especially in cold forging processes, data acquisition close to the deformation zone seems challenging due to the high surface pressure. Thus far, process parameters such as die temperature are mainly measured with state-of-the-art sensors, including standard thermocouples, which are integrated into the tooling system. The application of thin-film sensors has been tested in hot forging processes for local die temperature measurement. However, the process conditions regarding tribology and tool load in cold forging are even more difficult. In this contribution, the use of thin-film sensors, applied on a cold forging punch for cup backward extrusion, is subjected. The aim is to investigate the applicability of such thin-film sensors in cold forging with special emphasis on temperature measurement in cyclic forming processes. The thin-film sensor system and its manufacturing procedure by vacuum coating technology combined with microstructuring are described. With these thin-film sensors the cup backward cold extrusion of steel billets was investigated experimentally. Cyclic tool heating simulations with thermal parameter variations were performed as a reference to experimental results.

Thin-Film Sensor, Cold Forging, Cyclic Simulation

Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: GRÖTZINGER Karl C.1, SCHOTT Anna, REKOWSKI Martin, EHRBRECHT Bernd, HEHN Thorsten, GERASIMOV Dmitry, LIEWALD Mathias, Analysis of tool heating in cold forging using thin-film sensors, Materials Research Proceedings, Vol. 28, pp 2027-2036, 2023


The article was published as article 218 of the book Material Forming

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