• Transactions of Materials Processing
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• v.16 no.6
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• pp.479-487
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• 2007

Die life is generally estimated taking failure life and wear amount into consideration. In this study, the forging die life was investigated considering both of these two factors. The fatigue life prediction for the die was performed using the stress-life method, i.e. Goodman's and Gerber's equations. The Archard's wear model was used in the wear life simulation. These die life prediction techniques were applied to the die used in the forging process of the socket ball joint of a transportation system. A rigid-plastic finite element analysis for the die forging process of the socket ball was carried out and also the elastic stress analysis for the die set was performed in order to get basic data for the die fatigue life prediction. The wear volume of the die was measured using a 3-dimensional measurement apparatus. The simulation results were relatively in good agreement with the experimental measurements.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.4
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• pp.87-92
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• 1999

Generally the life of die is limited by fatigue fracture or dimensional inaccuracy originated from wear. In this paper to predict the fatigue life of die the stress and strain histories of die can be predicted by the analysis of elastic-plastic finite element method and the elastic analysis of die during the process analysis of workpiece. Also the stress-life curve of die material can be obtained through experiment. With the above to재 facts we propose the analysis method of prediction fatigue life in die,. In the proposed model the analysis of elastic-plastic finite element method for material is carried out by using ABAQUS. Surface force resulted from the contacting border of the die and workpiece is transformed into the nodal force of die to implement elastic analysis. besides the proposed analysis model of die is applied to extrusion die and forging. die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.67-70
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• 2000

The tool life is not long enough under sever forming condition in warm forging. The tool life is affected by wear heat fatigue plastic deformation and so on. Especially wear is one of the most serious factors for tool life. To increase tool life we should consider various factors like processing design die design die materials lubrication and cooling system This study design to obtain the steady state temperature of die by FEM analysis under several conditions of cooling. There are four cooling conditions in this study no cooling internal cooling external cooling and both internal and external cooling. With above obtained temperatures tool life is predicted using Archard's model that is considered softening of die. The effect of internal cooling system is better than that of externally cooled die. To predict the die life the steady state temperature is calculated by using mean temperature of die. Considering only wear the die life much longer as the cooling effect is bigger. The more accurate die life will be predicted if we consider heat crack as well as wear.

• Transactions of Materials Processing
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• v.12 no.4
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• pp.408-413
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• 2003

Dies may have to be replaced for a number of reasons, such as changes in dimensions due to die wear or plastic deformation, deterioration of the surface finish, break down of lubrication and cracking or breakage. In this paper, die cooling methods have been suggested to improve die service life considering die wear and plastic deformation in hot forging process. The yield strength of die decreases at higher temperatures and is dependent on hardness. Also, to evaluate die life due to wear, modified Archard's wear model has been proposed by considering the thermal softening of die expressed in terms of the main tempering curve. It was found that the use of die with cooling hole was more effective than that of direct cooling method to increase the die service life for spindle component.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.05a
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• pp.93-98
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• 1999

Generally, the - life of die is limited by fatigue fracture or dimensional inaccuracy originated from wear. In this paper, to predict the fatigue life of the dissimilar materials die, the stress and stxain histories of die can be predicted by the analysis of elasto-plastic finite element neth hod and the elastic analysis of die during the process analysis of workpiece. Using heat shrink fit analysis, initial stress of the k r t die is computed. Also, the stress-life curve of die material can be obtained through experiment. With the above two facts, we propose the analysis method of predicting fatigue life in die. In the proposed model, tlz analysis of elastic-plastic finite element method for material is carried out by using ABAQUS. Surface force resulted from the contacting border of the die and workpiece is tmnsformed into the nodal force of die to implement elastic analysis. Besides, the proposed analysis model of die is applied to the one material and the dissimilar materials extrusion die.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.264-271
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• 2015

In the current study, a method was proposed to quantitatively predict the wear and fatigue life of a shearing die in order to determine an effective replacement period for the die. The shearing die model of a retainer manufacturing process was used for the proposed method of quantitative life prediction. The retainer is produced through shearing steps, such as piercing and notching. The shearing die of the retainer is carefully controlled because the dimensional accuracy of the retainer is critical. The fatigue life for the shearing die was predicted using ANSYS considering S-N curves of STD11 and Gerber’s equation. The wear life for the shearing die was predicted using DEFORM-3D considering the Archard’s wear model. Experimental shearing of the retainer was conducted to verify the effectiveness of the proposed method for predicting die life. The fatigue failure of the shearing die was macroscopically measured. The wear depth was measured using a 3D coordinate measuring machine. The results showed that the wear and fatigue life in the FE analysis agree well with the experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.23-26
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• 2003

This paper explains the die cooling method for improving tool life in the hot forging process. In continuous forming operation such as hot forging process, performed at high speeds, temperature increases of several hundred degrees may be involved. Die hardness was reduced due to thermal softening. Factor of die fracture are wear and plastic deformation of die due to hardness reduction by high temperature. Because die service life was reduced due to this phenomenon during hot forging, quantified data for optimal die cooling method is required. The new developed techniques for predicting tool life applied to estimate the production quantity for a spindle component and these techniques can be applied to improve the tool life in hot forging process

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.1051-1055
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• 1997

Hot forging is widely used in the manufacturing of automotive component. The mechanical, thermal load and thermal softening which is happened by the high temperature die in hot forging. Tool life of hot forging decreases considerably due to the softening of the surface layer of a tool caused by a high thermal load and long contact time between the tool and workpieces. The service life of tools in hot forging process is to a large extent limited by wear, heat crack, plastic deformation. These are one of the main factors affecting die accuracy and tool life. It is desired to predict tool life by developing life prediction method by FE-simulation. Lots of researches have been done into the life prediction of cold forming die, and the results of those researches were trustworthy, but there have been little applications of hot forming die. That is because hot forming process has many factors influencing tool life, and there was not accurate in-process data. In this research, life prediction of hot forming die by wear analysis and plastic deformation has been carried out. To predict tool life, by experiment of tempering of die, tempering curve was obtained and hardness express a function of main tempering curve.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.4
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• pp.47-54
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• 2013

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.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.26-35
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• 2003

This study explains the effects of lubricant and surface treatment on hot forging die life. The mechanical and thermal load, and thermal softening which is happened by the high temperature of die, in hot and warm forging, cause die wear, heat checking and plastic deformation, etc. This study is fur the effects of solid lubricants and surface treatment condition for hot forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatment and lubricant are very important to improve die life for hot forging process. The main factors, which affect die hardness and heat transfer, are surface treatments and lubricants, which are related to thermal diffusion coefficient and heat transfer coefficient, etc. For verifying these effects, experiments are performed for hot ring compression test and heat transfer coefficient in various conditions as like different initial billet temperatures and different loads. The effects of lubricant and surface treatment for hot forging die life are explained by their thermal characteristics. The new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.