Evaluation of Sheet Metal Covers to Improve Tool Life in Forging Prof. Dr.-Ing. L. Schaeffer*, J. Zottis, Dr. Ing. A. Brito, Laboratório de Transformação Mecânica – UFRGS Prof. Dr.-Ing. G. Hirt, M. Wolfgarten*, Y. Yu Institut für Bildsame Formgebung – RWTH Aachen University *Presenting authors
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Evaluation of Sheet Metal Covers to
Improve Tool Life in Forging
Prof. Dr.-Ing. L. Schaeffer*, J. Zottis, Dr. Ing. A. Brito,
Laboratório de Transformação Mecânica – UFRGS
Prof. Dr.-Ing. G. Hirt, M. Wolfgarten*, Y. Yu
Institut für Bildsame Formgebung – RWTH Aachen
University
*Presenting authors
Slide 2
Motivation
Tooling costs stand up to 15-35% of total costs
Main failure of forging die: abrasive wear
Most failures appear on the surface
Method of surface protection
– Surface treatment (Nitriding, PVD…)
– Coating
– Die insert
Tool repair and exchange is still required
To protect forging tool, decrease tooling costs
Inspired by the exchangeable cutting tool insert
For Making the surface of forging die
“exchangeable”
Wear
Mechanial
fatigue
Plastic
deformation
Thermal
fatigue
Failures
Out of use
Hot forging die Forging
Traditional forging
Slide 3
Motivation
Inexpensive and easy-to-exchange sheet metal
as a protective die cover
Die cover concept
– Failures will only affect die covers
– Can be exchanged quickly
– Thermal load will be reduced
– Economical
Fix the die cover Forging
Take out forging
pieces
Take out the die cover
after N forging pieces
Out of use
Recycle use
Forging die
Forging with die covers
Slide 4
Motivation
Slide 5
Conclusions from the previous project stage
Materials were selected based upon their mechanical and
thermal properties.
Different geometries were developed to define the
application range of this concept.
The protection effect of die covers was proved both by
simulations and experiment.
Two geometries were validated by experiment and the die
cover reached 10 forging cycles.
Open questions:
– Wrinkling and thinning problems
– Application on more complex geometries
Slide 6
Objectives of the 2nd phase
Investigation of possibilities to improve the boundary
conditions
– Influence of the friction coefficient on the tensile stresses
within the die cover
– Test of enhanced sheet fixation
Development of a suitable die geometry
– Investigation of 3D geometries
– Investigation of axisymmetric geometries
Investigation of multi-stage forging processes
– Analysis of multi-stage forging process with reduced
tangential movement in forging stages
– Investigation of the “finisher” step
Slide 7
General information
Publications
– Publications in Journals:
First experimental and numerical study on the use of sheet metal die covers for wear