Journal of the Korean Society of Manufacturing Process Engineers (한국기계가공학회지)

The Korean Society of Manufacturing Process Engineers (한국기계가공학회)
권호 표지

Finite Element Simulation on Prediction of an Asymmetric Hot Forging Die Life Based on Wear

마멸에 기초한 비대칭 열간단조 금형수명 예측에 관한 유한요소 시뮬레이션

  • Published : 2013.08.30
⟨ Previous Next ⟩

Abstract

The main cause of die failure in hot forging is wear. Die wear directly generates the gradual loss of part tolerances, thereby causing deterioration in the dimensional accuracy of a forged part. It is very important to estimate forging cycles, called as die life, at which the die should be repaired or replaced. In this study, in order to estimate the hot forging die life, the finite element simulation of wear on an asymmetric part like a ball joint socket used in vehicle was carried out based on Archard's model. Finite element simulation results were compared with wear amounts of a used die that were measured using a contact stylus profilometer. The simulation results were in relatively good agreement with measurements obtained from the virtual die which was used by 7,000 forging cycles in a forging industry. Consequently, the die life in the hot forging of the ball joint socket was estimated by 10,500 forging cycles on the finisher die.

Keywords

References

  1. Lange, K., "Cost Minimization in Small Quantity Production of Stepped Shafts by Combined NC-Radial Forging and NC-Turning - A New Approach to Flexible Manufacturing System", Annals of the CIRP, 1985.
  2. Cser, L., Geiger, M. and Lange, K., "Tool Life and Tool Quality in Bulk Metal Forming", Proc. Int. Mech. Engrs., Vol. 207, pp.223-239, 1993.
  3. Kim, H. Y., Kim, J, J. and Kim N. S., "An Analysis of Hot Closed-Die Forging to Reduce Forging Load and Die Wear", Proc. of the KSME 1993 Spring Conference, pp.839-844, 1993.
  4. Kang, J. H., Park, I. W., Jae, J. S. and Kang, S. S., "A Study on Prediction of Die Life of Warm Forging by wear", J. of the Korean Society for Tech. Pl., Vol. 7, No. 3, pp.274-290, 1998.
  5. Archard, J. F., "Contacts and Rubbing of Flat Surfaces", J. of Applied Physics, Vol. 24, pp.981-988, 1953. https://doi.org/10.1063/1.1721448
  6. Liou, M. J. and Hsiao, H. S., "Prediction of Wear in High Speed Hot Upset Forging", ERC/NSM Report, No. 33-39, 1989.
  7. Hansen, P. H. and Bay, N., "A Flexible Computer Based System for Prediction of Wear Distribution in Forming Tools", Advanced Tech. of Pl., Vol. 1, pp.19-26, 1990. https://doi.org/10.1002/pat.1990.220010104
  8. Rooks, B. W., "The Effect of Die Temperature on Metal Flow and Die Wear During High Speed Hot Forging", Proc, 15th Inter. MTDR Conference, England, No. 4, pp.487-495, 1974.
  9. Kim, T. H., Kim, B. M. and Chio, J. C., "Prediction of die wear in the wire-drawing process", J. of Mater. Proc. Tech., Vol. 65, pp.11-17, 1997. https://doi.org/10.1016/S0924-0136(96)02235-2
  10. Tronel, Y. and Chenot, J. L.. "Prediction of Tool Wear Using Finite Element Software for the Three-Dimension Simulation of the Hot- Forging Process", J. of Mater. Proc. Tech., Vol. 31, pp.255-263, 1992. https://doi.org/10.1016/0924-0136(92)90026-O
  11. Painter, B., Shivpuri, R. and Altan, T., "Prediction of die wear during hot extrusion of engine valves", J. of Mater. Proc. Tech., Vol. 59, pp.132-143, 1996. https://doi.org/10.1016/0924-0136(96)02294-7
  12. Deform-3D User Manual, V5.0, SFTC.
  13. ASM Metals Handbook Volume 1 - Properties and Selection Irons, Steels, and High-Performance Alloy, The Materials Information Society, pp.728-732, 2005.
  14. Deform-3D and Deform material library, Scientific Forming Technologies Corporation, http://www.deform.com
  15. Kim, Y. J. and Choi, C. H., "A Study on Life Estimation of Hot Forging Die", International Journal of Precision Engineering and Manufacturing, Vol. 8, No. 1, pp.1-5, 2008.
  16. RapidForm 2004 Tutorial, INUS Technology Inc., 2003.