Application of a measuring arm with an integrated laser scanner in the analysis of the shape changes of forging instrumentation during production

Gronostajski, Z.; Hawryluk, Marek; Kaszuba, M.; Ziemba, Jacek

doi:10.17531/ein.2016.2.6

Cited by 24 publications

(25 citation statements)

References 10 publications

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“…A similar situation takes place for the classic Lorenz curve, which, close to the end of the normal operation period, usually transforms into the state of accelerated wear. It should be emphasized that the shape of the wear curve can differ in the case of other tools, which has been confirmed by the authors' studies, presented in [11].…”

Section: Advanced Wear Analysissupporting

confidence: 71%

Development of a Method for Tool Wear Analysis Using 3D Scanning

Hawryluk¹,

Ziemba²,

Dworzak³

2017

Metrology and Measurement Systems

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The paper deals with evaluation of a 3D scanning method elaborated by the authors, by applying it to the analysis of the wear of forging tools. The 3D scanning method in the first place consists in the application of scanning to the analysis of changes in geometry of a forging tool by way of comparing the images of a worn tool with a CAD model or an image of a new tool. The method was evaluated in the context of the important measurement problems resulting from the extreme conditions present during the industrial hot forging processes. The method was used to evaluate wear of tools with an increasing wear degree, which made it possible to determine the wear characteristics in a function of the number of produced forgings. The following stage was the use it for a direct control of the quality and geometry changes of forging tools (without their disassembly) by way of a direct measurement of the geometry of periodically collected forgings (indirect method based on forgings). The final part of the study points to the advantages and disadvantages of the elaborated method as well as the potential directions of its further development.Keywords: 3D scanning, measurements and volumetric analysis of tools wear, improve a durability of forging tools.

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Section: Advanced Wear Analysissupporting

confidence: 71%

Development of a Method for Tool Wear Analysis Using 3D Scanning

Hawryluk¹,

Ziemba²,

Dworzak³

2017

Metrology and Measurement Systems

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“…from a laboratory to a forging unit), for the purpose of rapid measurement and analysis of results, e.g. : heavy die, steel plate, etc., without the need to dismount tools and interrupt production in order to assess critical geometric features [11][12]18]. Thanks to their mobility and universality, measuring arms are also an alternative to coordinate measuring machines in applications permitting lower accuracy of measurement [21,31].…”

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

“…Thanks to their mobility and universality, measuring arms are also an alternative to coordinate measuring machines in applications permitting lower accuracy of measurement [21,31]. Publications concerning the application of scanning measuring techniques can be found in the available literature, mainly for final quality control of products [24, 29,], but increasingly often, also for control of forging tools and instrumentation [11][12][13]18]. It should be noted that the application of scanning techniques only allows for determination of geometric changes relative to the assumed nominal object, i.e.…”

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Dworzak¹,

Hawryluk²,

Ziemba³

2017

Adv. Sci. Technol. Res. J.

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This article presents a wear analysis of die inserts used in the hot forging process of a forked forging (yoke), an element applied in steering systems of passenger vehicles. Studies involved the application of an original reverse scanning method intended for rapid and reliable wear analysis of forging tools (with complicated shape) affording easy assessment without the need to dismount tools from the forging unit. The developed method involves analysis of progressive wear of forging tools based on measurements (scanning) of forgings periodically collected from the process and constitutes a useful tool for measurement and testing. As the authors' earlier works have demonstrated, the proposed new approach to analysis of tool wear with the application of reverse 3D scanning has proven successful in multiple instances in the case of axially symmetrical objects. The presented results of studies indicate that it is possible to utilize the expanded method to analyze the lifetime of forging tools, including tools with complex geometry. Application of the reverse scanning method allows for continuous and practical monitoring of the condition of forging tools over the course of the forging process and should have a positive impact on improving production output and reducing production costs.

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“…This method was discussed in detail in the study [23], in which the authors analysed and validated it based on the hot forging process of a lid forging.…”

Section: Macroscopic Analysis Combined With Scanningmentioning

confidence: 99%

“…Tool durability is a complex issue, and tool wear significantly lowers the quality of the produced forgings. This subjects were widely described by authors in following works [23][24][25]. In the work [24], the author concentrates on selected methods, which provide the highest effectiveness in the improvement of the forging tool life, used in the industrial processes of die forging, based on own research and experiments realized in cooperation with the forging industry.…”

Section: Introductionmentioning

confidence: 99%

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Gronostajski¹,

Hawryluk²,

Kaszuba³

et al. 2017

Archives of Metallurgy and Materials

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This study is focused on tools used in the industrial process of hot forging of a front wheel forging (gear wheel) manufactured for the automotive industry. Five different variants were applied for the tools: 3 die inserts were coated with three different hybrid layers (PN + PVD type), i.e. AlCrTiN, AlCrTiSiN and CrN, one insert was only nitrided, and one was pad welded, to improve tool durability. The tool wear was analysed and represented by the material degradation on the working surface, based on the 3D scanning and the material growth of the periodically collected forgings. Additionally, the scanned tools were divided into two areas, in which it was found, based on the analysis, that various degradation mechanisms are predominant. Microstructural tests and hardness measurements of the analyzed tools were also performed. Based on the results, it was found that, in the central part of the die insert, thermo-mechanical fatigue, abrasive wear and plastic deformation occurred, while in the area of the bridge insert, only abrasive wear could be observed. For these areas, the loss of material was determined separately. It was established that the use of the GN+CrN and GN+AlCrTiN hybrid layers on forging tools improves their durability, while the best results in the central area were observed on the tool with the GN+CrN layer, which is the most resistant to thermo-mechanical fatigue. In the second analyzed area, good wear resistance occurred on GN+CrN, GN+AlCrTiN and pad welded inserts, for which, together with the increase of the forging number, a proportional, slight growth of the loss of material occurred.

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Application of a measuring arm with an integrated laser scanner in the analysis of the shape changes of forging instrumentation during production

Cited by 24 publications

References 10 publications

Development of a Method for Tool Wear Analysis Using 3D Scanning

Development of a Method for Tool Wear Analysis Using 3D Scanning

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

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