WEAR ANALYSIS OF HOT FORGING DIES
ABACHI, Siamak
M. S., Department of Mechanical Engineering
Supervisor: Prof. Dr. Metin AKKÖ / K
Co-Supervisor: Prof. Dr. Mustafa lhan GÖ / 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° / C and die temperature of 300° / 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¥ / 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¥ / 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.
| Identifer | oai:union.ndltd.org:METU/oai:etd.lib.metu.edu.tr:http://etd.lib.metu.edu.tr/upload/12605706/index.pdf |
| Date | 01 December 2004 |
| Creators | Abachi, Siamak |
| Contributors | Akkok, Metin |
| Publisher | METU |
| Source Sets | Middle East Technical Univ. |
| Language | English |
| Detected Language | English |
| Type | M.S. Thesis |
| Format | text/pdf |
| Rights | To liberate the content for public access |
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