Synergetic approach to die wear modelling in hot forging process

by

Synergetic approach to die wear modelling in hot forging process

Marek Wilkus, Danuta Szeliga, Łukasz Rauch, Maciej Pietrzyk

AGH University of Science and Technology, al. Mickiewicza 30, 30-059 Kraków.

DOI:

https://doi.org/10.7494/cmms.2017.4.0603

Abstract:

A proposition of the hybrid model of the tool wear in hot forging is described in the paper. The idea of the model was based on distinguishing various mechanisms of the tool wear and evaluation of the mutual influence of these mechanisms. The analysis of factors, cumulative wear of which is mutually dependent, confirmed that all mechanisms influence each other in some way. To cover this, the hybrid die wear model was proposed which includes significance of each mechanism and the mutual relation between them. Additionally, to include change of material parameters, modification of these parameters was account for by a feedback, passing modified die geometry and optionally material parameters into the next iteration of die wear modelling. Developed model consists of the FE simulation to which the following process parameters are supplied by the user: wear mechanisms blocks containing adequate models, significance models and extrapolation routines for results or input parameters, component to apply computed wear value as a die geometry and control the computation of multi-iteration wear prediction. Some mechanisms blocks contain additional components for computing correction of surface parameters altered by thermomechanical fatigue, cracks or increased porosity. Numerical tests of the model were performed for the second operation in the forging of clutch wheel. Comparison of predictions and measurements confirmed improvement of the model predictive capability when synergy of the three mechanisms was accounted for.

Cite as:

Wilkus, M., Szeliga, D., Rauch, Ł., Pietrzyk, M. (2017). Synergetic approach to die wear modelling in hot forging process. Computer Methods in Materials Science, 17(4), 195 – 206. https://doi.org/10.7494/cmms.2017.4.0603

Article (PDF):

Keywords:

Hot forging, Finite element modelling, Die wear, Wear mechanisms, Synergetic model

References:

Abachi, S., Akkok, M., Gokler, M.I., 2010, Wear analysis of hotforging dies, Tribology International, 43, 467-73.

Andrietti, S., Chenot, J.-L., Bernacki, M., Bouchard, P.-O.,Fourment, L., Hachem, E., Perchat, E., 2015, Recentand future developments in finite element metalforming simulation, Computer Methods in MaterialsScience, 15, 265-293.

Altan, T., Ngaile, G., Shen, G., (eds), 2004, Cold and hot forging:Fundamentals and applications, ASM International,Metals Park.Archard, J.F., 1953, Contact and rubbing of flat surfaces, Journalof Applied Physics, 24, 981-988.

Behrens, B.A., Schaefer, F., 2005, Prediction of wear in hotforging tools by means of finite-element analysis, Journalof Materials Processing Technology, 167, 309-315.

Chen, C., Wang, Y., Ou, H., He, Y., Tang, X., 2014, A reviewon remanufacture of dies and moulds, Journal of CleanerProduction, 64, 13-23.

Chenot, J.-L., Fourment, L., Ducloux, R., Wey, E., 2010, Finiteelement modelling of forging and other metal formingprocesses, Proc. 13th ESAFORM Conf. on MaterialForming, Supplement 1, (eds), Ceretti, E., Giardini, C.,Brescia, 359-362.

Choi, C., Groseclose, A., Altan, T., 2012, Estimation of plasticdeformation and abrasive wear in warm forging dies,Journal of Materials Processing Technology, 212,1742–1752.

Danzl, R., Helmli, F., Scherer, S., 2011, Focus variation – arobust technology for high resolution optical 3D surfacemetrology, Strojniški vestnik – Journal of Mechanicalengineering, 57, 245-256Diko, F., 1992, Metal flow simulation and design of dies forclosed die forging, PhD thesis, Dublin City University.

Gronostajski, Z., Hawryluk, M., Niechajowicz, A.,Zwierzchowski, M., Kaszuba, M., Bedza, T., 2011, Applicationof the scanning laser system for the wear estimationof forging tools, Computer Methods in MaterialsScience, 11, 425-431.

Gronostajski, Z., Kaszuba, M., Hawryluk, M., Zwierzchowski,M., 2014a, A review of the degradation mechanisms ofthe hot forging tools, Archives of Civil and MechanicalEngineering, 14, 528-539.

Gronostajski, Z., Będza, T., Kaszuba, M., Marciniak, M., Polak,S., 2014b, Modelling the mechanisms of wear in forgingtools, Obróbka Plastyczna, 25, 301 -315.

Gronostajski, Z., Hawryluk, M., Kaszuba, M., Marciniak, M.,Niechajowicz, A.,Polak, S., Zwierzchwoski, M., Adrian,A., Mrzygłód, B., Durak, J., 2016, The expert systemsupporting the assessment of the durability of forgingtools, International Journal of Advanced ManufacturingTechnology, 82, 1973–1991.

Groseclose, A.R., 2010, Estimation of forging die wear and cost,MSc thesis, The Ohio State University.Kang, J.H., Park, I.W., Jae, J.S., Kang, S.S., 1998, A study ondie wear model of warm and hot forgings, Metals andMaterials, 4, 477-483.

Kaur, J., Pabla, B.S., Dhami, S.S., 2016, A review on field areasof research in forging process using FEA, InternationalJournal of Engineering Research and Technology, 5,383-393.

Lavtar, L., Muhic, T., Kugler, G., Tercelj, M., 2011, Analysis ofthe main types of damage on a pair of industrial dies forhot forging car steering mechanisms, Engineering FailureAnalysis, 18, 1143-1152.

Lee, R.S., Jou, J.L., 2003, Application of numerical simulationfor wear analysis of warm forging die, Journal of MaterialsProcessing Technology, 140, 43-48.

Lee, H.C., Lee, Y., Lee, S.Y., Choi, S., Lee, D.L., Im, Y.T.,2008, Tool life prediction for the bolt forming processbased on high-cycle fatigue and wear, Journal of MaterialsProcessing Technology, 201, 348-353.

Liu, C., 2007, Modeling of water and lubricant sprays in hotmetal working, PhD thesis, The Ohio State University.Neupane, R., Farhat, Z., 2015, Wear resistance and indentationbehavior of equiatomic superelastic TiNi and 60NiTi,Materials Sciences and Applications, 6, 694-706.

Osipov, N., 2017, From calculating the forming to estimatingthe service life of mechanical components, presented atTransvalor International Simulation Days, Nice, 2017.

Oyane, M., Sato, T., Okimoto, K., Shima, S., 1980, Criteria forductile fracture and their applications, Journal of MechanicalWorking Technology, 4, 65-81.

Rauch, Ł., Chmura, A., Gronostajski, Z., Zwierzchowski, M.,Pietrzyk, M., 2016, Cellular automata model for predictionof crack initiation and propagation in hot forgingtools, Archives of Civil and Mechanical Engineering, 16,437-447.

Simionato, M., Ghiotti, A., Bruschi, S., 2008, Billet croppingnumerical modelling: an approach based on inverseanalysis, International Journal of Material Forming, 1,33-36.

Wang, P.-Y., Jian, Y.-T., 2012, The forging dies design andwear analysis of straight bevel gear, Advanced ScienceLetters, 8, 7-12.

Wilkus, M., Polak, S., Gronostajski, Z., Kaszuba, M., Rauch, Ł.,Pietrzyk, M., 2015, Modelling of the die wear in the hot forging process using the Archard model, ComputerMethods in Materials Science, 15, 311-321.

Wilkus M., Rauch Ł., Gronostajski Z., Polak S., Pietrzyk M.,2016, Computer system for identification of tool wearmodel in hot forging, Proc. Conf. NUMIFORM, Troyes(e-book).