Design of a forging process to individually examine thermal, mechanical and tribological stress in the tool surface zone

Design of a forging process to individually examine thermal, mechanical and tribological stress in the tool surface zone

BEHRENS Bernd-Arno, MÜLLER Felix, LORENZ Uwe

download PDF

Abstract. The surface layer of hot forging tools undergoes local microstructural changes due to high thermo-mechanical and tribological loads. Tools made of hot working steel are usually pre-heated and experience extreme heating and cooling during each forging cycle, affecting their local wear behaviour significantly. Therefore, the analysis of these tool surface layers in die forging and their effect on wear behaviour is of great importance. The microstructural changes in the tool surface layer mainly depend on thermal loads, which are highly influenced by the tool cooling system. A process and a suitable tool system are developed to vary the thermal and mechanical loads on the tool surface layer and fundamentally examine the resulting microstructural changes.

Keywords
Forging Die, Tool Design, Numerical Investigation, Temperature Monitoring, Online Measurement

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: BEHRENS Bernd-Arno, MÜLLER Felix, LORENZ Uwe, Design of a forging process to individually examine thermal, mechanical and tribological stress in the tool surface zone, Materials Research Proceedings, Vol. 28, pp 573-582, 2023

DOI: https://doi.org/10.21741/9781644902479-62

The article was published as article 62 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] R. Seidel, H. Luig, Friction and wear processes in hot die forging, in: H. Berns et al., New Mat. Processes Experiences for Tooling, CH-Andelfingen, MAT SEARCH, 1992, pp.467-480.
[2] K. Lange, L. Cser, M. Geiger, Tool life and tool quality in bulk metal forming, CIRP Ann. Manuf. Technol. 41 (1992) 667-675. https://doi.org/10.1016/S0007-8506(07)63253-3
[3] S. Joshy, K.R. Jayadevan, A. Ramesh, Influence of in-service thermal softening on wear and plastic deformation in remanufactured hot forging dies, Eng. Res. Express 1 (2019) 025024. https://doi.org/10.1088/2631-8695/ab504f
[4] W. Stute-Schlamme, Konstruktion und thermomechanisches Verhalten rotationssymmetrischer Schmiedegesenke, Dissertation, Universität Hannover, 1981
[5] B.J. Griffiths, D.C. Furze, Tribological advantages of white layers produced by machining, ASME Trans., J. Trib. 109 (1987) 338-342. https://doi.org/10.1115/1.3261363
[6] Y.Y. Yang, H.S. Fang, W.G. Huang, A study on wear resistance of the white layer, Tribol. Int. 29 (1996) 425-428. https://doi.org/10.1016/0301-679X(95)00099-P
[7] B.-A. Behrens, J. Puppa, U. Lorenz, Development of an intelligent hot-working steel to increase the tool wear resistance, The 11th TOOLING 2019 conference & exhibition, 2019
[8] L. Xu, S. Clough, P. Howard, D. StJohn, Laboratory assessment of the effect of white layers on wear resistance for digger teeth, 1995
[9] J. Puppa, B.-A. Behrens, Optimization of cooling and lubrication for nitrided and ceramic-coated hot forging dies, Appl. Mech. Mater. 794 (2015) 97-104. https://doi.org/10.4028/www.scientific.net/AMM.794.97
[10] A. Hensel, T. Spittel, Kraft- und Arbeitsbedarf bildsamer Formgebungsverfahren, Verlag Grundstoffindustrie, 1978
[11] B.-A. Behrens, J. Gibmeier, C. Kock, Investigations on Residual Stresses within Hot-Bulk-Formed Components Using Process Simulation and the Contour Method, Metals 11 (2021) 566. https://doi.org/10.3390/met11040566
[12] Gesellschaft für metallurgische Technologie- und Softwareentwicklung mbH, „MatILDa,“ [Online]. Available: https://www.gmt-stahl.de/en/matilda-2/. (accessed on 08 January.2020)
[13] I.Y. Malik, U. Lorenz, B.-A. Behrens, Microstructure and wear behaviour of high alloyed hot-work tool steels 1.2343 and 1.2367 under thermo-mechanical loading. Proc. IOP Conf. Ser. Mater. Sci. Eng. 629 (2019) 012011. https://doi.org/10.1088/1757-899X/629/1/012011
[14] W. Rankine, On the stability of loose earth. Philos. Trans. Royal Soc. London 147 (1857) 9-27. https://doi.org/10.1098/rstl.1857.0003