• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1998.03a
• /
• pp.88-93
• /
• 1998

The service life of tools in metal forming process is to a large extent limited by wear, fatigue fracture and plastic deformation. In warm forging processes wear is the predominant factor for operating lives of tools. To predict tool life by wear, Archard's wear model is generally applied. Usually hardness of die is considered to be a function of temperature in Archard's wear model. But hardness of die is a function of not only temperature but also operating time of die. To consider softening of die by repeated operations, it is necessary to express hardness of dies by a function of temperatures and operating time. By experiment of reheating of dies, die softening curves were obtained. Finally modified Archard's wear model in which hardness of die was expressed as a function of main tempering curve was proposed.

• Transactions of Materials Processing
• /
• v.7 no.3
• /
• pp.274-281
• /
• 1998

The service life of tools in metal forming process is to a large extent limited by wear, fatigue fracture and plastic deformation. In elevated temperature forming processes wear is the predominant factor for tool operating life. To predict tool life by wear Achard's model is generally applied. Usually hardness of die is considered to be a function of temperature. But hardness of die is a function of not only tem-perature but also operating time of die. To consider softening of die by repeated operation it is necessary to express hardness of die by a function of a function of temperature and time. By experiment of reheating of die softening curve was obtained and applied to suggest modified Archard's Model in which hardness is a function of main tempering curve.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.12 no.3
• /
• pp.7-12
• /
• 2013

In Die casting process, the problem of die degradation is often issued. In oder to increase of die life the material degradation of die steel was investigated using test core pins. Three test core pins were positioned in front of the gate entry and observed washout and soldering resistance during Mg die casting process. The test parameters are set as different commercial die materials, coatings condition and hardness of die surface. Usign 220t magnesium die casting machine was employed to cast AZ91 magnesium alloys. After 150 shots, macroscopic observation of die surface was carried out. Additional 50 cycles later, test pins were chemically cleaned with 5% HCl aqueous solution to find out the existence of washout and soldering layers. Microstructural characterization of die surface and the die roughness measurement were performed together. Computational simulation using AnyCasting program was also beneficial to correlate the extent of die damage with the position of test pin inside die cavity. As results, the optimal combination of die steel with productive coating as well as its hardness was drawn out. it will be helpful to decide the material and condition considering increasing of tool life.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1998.06b
• /
• pp.54-59
• /
• 1998

In this study, two kinds of life prediction method for hot forming die are developed . One is empirical method requiring some experiment that evaluate thermal softening of die material accoring to operating conditions. The other is analyticl method that calcuate wear quantity of die occuring during the forming process. Wear is a predominant factor as well as plastic deformation and heat checking . And, these methods are applied to prodict tool life real die producting part for automobile. Thus , the applicability and the accuracy of the presented methods are investigated. Using the verified life prediction method above , optimal blocker die design minimizing the finisher die is done.

• Transactions of Materials Processing
• /
• v.30 no.4
• /
• pp.172-178
• /
• 2021

The cold forging process induces material deformation in an enclosed space, generating a very high forging load. Therefore, it is mainly designed as a multi-stage process, and fatigue failure occurs in forging die due to cyclic load. Studies have been conducted previously to quantitatively predict the fatigue limit of cold forging dies, however, there was a limit to field application due to the large error range and the need for expert intervention. To solve this problem, we conducted a study on the introduction of a real-time forging load measurement technology and an automated system for quantitative prediction of die life cycle. As a result, it was possible to reduce the error range of the quantitative prediction of die life cycle to within ±7%, and it became possible to use the die life cycle calculation algorithm into an automated system.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.9 no.2
• /
• pp.281-285
• /
• 2008

Die hobbing is one of the dieblock manufacturing methods of cold forging die, which makes the upper side of dieblock indented using master punch, hobb to produce impression not using cutting work. SKD11, alloy tool steel was used as the material of dieblock and stainless sheet metal was used as product material in cold forging work. The life span of the die was 6,000 strokes. In this research, the material of dieblock was changed into SKH51, the high speed tool steel and the product material was S45C, the carbon steel in the cold forging work. The life span of the die was 21,000 strokes, which is 350% of the life span of the die using the former method.

• Transactions of Materials Processing
• /
• v.9 no.4
• /
• pp.413-420
• /
• 2000

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of front housing part of aircon compressor, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the filling and solidification stages for the sound casting products. Two cases of casting design that have different types of gating system are considered in the analysis. The potential sites where the casting defects may occur is examined by computer simulation and an improved design process is proposed. Also the effect of partial squeeze on the quality of casting products is considered and the optimal time lag after filling process is determined. For the die-stability, the effect of operational parameters such as die temperature, heat cycle and spot cooling on the die life has also been analyzed.

• Transactions of Materials Processing
• /
• v.11 no.3
• /
• pp.211-216
• /
• 2002

The mechanical and thermal load, and thermal softening occuring by the rush temperature of die, in warm and hot forging, cause wear, heat cracking and plastic deformation, etc. This paper describes the effects of solid lubricants and surface treatments for warm forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatments and lubricants are very important to hot and warm forging process. The main factors affecting die hardness and heat transfer, are surface treatments and lubricants, which are related to heat transfer coefficient, etc. To verify the effects, experiments are performed for heat transfer coefficient in various conditions - different initial billet temperatures and different loads. Carbonitriding and ionitriding are used as surface treatments, and oil-base and water-base graphite lubricants are used. The effects of lubricant and surface treatment for warm and hot forging die life are explained by their thermal characteristics, and 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.

• Journal of Powder Materials
• /
• v.14 no.6
• /
• pp.367-371
• /
• 2007

P/M high speed steel (1.26% C, 4.42% Cr, 6.54% W, 4.92% Mo, 3.21 % V, 8.77% Co, bal. Fe) was applied to hot former die. It showed that the die life became 2.7 times higher than that of cast/wrought SKH 55 tool steel which is commercially used. The increase of die life was corresponding to the improved hardness and transverse rupture strength of PM high speed steel due to the finer grain and carbide as well as the uniform carbide distribution. The P/M high speed steel with the promoted die life could be an alternative to the conventional SKH55.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.5 no.6
• /
• pp.511-514
• /
• 2004

Punch and die plate which are press die parts can be made using machine tool or using both machine tool and W-EDM. When machine tool is used, the die life is 2,000,000 to 230,000 strokes. But with W-EDM, the die life is 700,00 to 800,000 strokes. This can be caused by the process deformation layer after W-EDM. SEM pictures of processed section before and after W-EDM are taken to see if the process deformation layer appeared. Also the elimination method is studied.