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WEAR ANALYSIS OF HOT FORGING DIES ABACHI, Siamak M. S., Department of Mechanical Engineering Supervisor: Prof. Dr. Metin AKK&Ouml / K Co-Supervisor: Prof. Dr. Mustafa lhan G&Ouml / KLER December 2004, 94 pages The service lives of dies in forging processes are to a large extent limited by wear, fatigue fracture and plastic deformation, etc. In hot forging processes, wear is the predominant factor in the operating lives of dies. In this study, the wear analysis of a closed die at the final stage of a hot forging process has been realized. The preform geometry of the part to be forged was measured by Coordinate Measuring Machine (CMM), and the CAD model of the die and the worn die were provided by the particular forging company. The hot forging operation was carried out at a workpiece temperature of 1100&deg / C and die temperature of 300&deg / C for a batch of 678 on a 1600-ton mechanical press. The die and the workpiece materials were AISI L6 tool steel and DIN 1.4021, respectively. The simulation of forging process for the die and the workpiece was carried out by Finite Volume Method using MSC.SuperForge. The flow of the material in the die, die filling, contact pressure distribution, sliding velocities and temperature distribution of the die have been investigated. In a single stroke, the depth of wear was evaluated using Archard&rsquo / s wear equation with a constant wear coefficient of 1&yen / 10-12 Pa-1 as an initial value. The depth of wear on the die surface in every step has been evaluated using the Finite Volume simulation results and then the total depth of wear was determined. To be able to compare the wear analysis results with the experimental worn die, the surface measurement of the worn die has been done on CMM. By comparing the numerical results of the die wear analysis with the worn die measurement, the dimensional wear coefficient has been evaluated for different points of the die surface and finally a value of dimensional wear coefficient is suggested. As a result, the wear coefficient was evaluated as 6.5&yen / 10-13 Pa-1 and considered as a good approximation to obtain the wear depth and the die life in hot forging processes under similar conditions.

La qualité des pièces découpées pour les industries électroniques et micromécaniques est appréciée via trois critères principaux : le niveau de bavure, l’aspect du bord découpé et la précision dimensionnelle. Or, l’étude de la qualité des pièces découpées ne peut se faire sans une compréhension de l’usure des poinçons. Ainsi, des méthodes de mesure en continu et in situ de l’usure ont été mises au point et validées, soit l’activation superficielle et la mesure par double réplique. Ainsi, il a été possible de suivre l’influence d’un certain nombre de paramètres du procédé sur l’évolution de l’usure lors du découpage. Par ailleurs, nous avons mis au point une méthode de quantification de la bavure sur la totalité du contour découpé. Il a ainsi été possible d’étudier l’évolution de la bavure au cours de la découpe. L’aspect des bords découpés a été examiné grâce à des relevés topographiques permettant le suivi de son évolution. Ainsi, une corrélation entre la cinétique d’usure des poinçons et l’apparition de la bavure a été établi. De plus, une simulation expérimentale de l’usure des poinçons a été entreprise. Un dispositif expérimental de tribométrie a été conçu et installé sur la ligne de presse, simulant les conditions de frottement d’un poinçon sur une tôle. Il a permis d’évaluer l’abrasivité des tôlesminces vis-à-vis des poinçons. Par ailleurs, une modélisation numérique de l'opération de découpage par éléments finis a été entreprise, permettant d’approcher le profil d’usure d’un poinçon de géométrie cylindrique. Et par conséquent la possibilité de prédire son évolution en fonction du nombre de pièces découpées devient accessible en fonction des paramètres du procédé / The blanked parts quality for electronic and amicromechanical industry is assessed using threemain criterions: the burr amount, the appearance ofthe cut edge and dimensional accuracy. However, thestudy of the quality of the blanked pieces can not bedone without an understanding of the punches wear.Thus, methods for continuous and in-situ wearmeasurements have been developed and validated:Thin Layer Activation and measurement by doublereplica. Thus, it was possible to follow the influenceof process parameters on the wear evolution duringblanking.In addition, we have developed a method forquantifying the burr on the entire blanked contour. Itwas thus possible to study the evolution of the burrduring blanking. The appearance of the cut edges wasexamined by means of topographic survey for monitoringits evolution. Thus, a correlation between the kinetics ofpunches wear and the appearance of the burr has beenestablished. In addition, an experimental simulation ofpunches wear was undertaken. An experimentaltribometry was designed and installed on the press line,simulating the conditions of friction of a punch on onesheet. It evaluated the abrasiveness of thin sheets againstthe punches.Additionally, a numerical modelling of blanking wasundertaken to approach the wear profile of a punch ofcylindrical geometry. And therefore the ability to predictits evolution contingent on the number of blanked pieces becomes available depending on process parameters