Damage, Lifetime, and Repair of Forging Dies

Buchmayr, Bruno

doi:10.1007/s00501-016-0566-3

Cited by 27 publications

(18 citation statements)

References 5 publications

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“…This tool steel is hard to machine because of the high cutting tension due to its alloy content [3]. Replacing dies represent between 10% and 30% of the cost of a forged part [4], which enforces the need to decrease this percentage. In that sense, a proper forging process must take into account how the die is manufactured and during the forging process, protect and lubricate.…”

Section: Introductionmentioning

confidence: 99%

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

et al. 2020

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In the forging industry, surface quality and surface treatments of dies are crucial parameters to extend their life. These components are usually machined by milling or by Electrical Discharge Machining (EDM), and the final surface roughness depends on the machining techniques and operational conditions used in its fabrication. After milling, a nitriding treatment is widely applied to extend its service life. Nevertheless, no scientific report that informs about nitriding after EDM has been found. Accordingly, this work focuses on the wear and friction behavior of pins made of brass and medium carbon steel sliding over AISI H13 discs, made by wire EDM in the conditions of finishing and roughing. The discs are plasma nitride, and their effect on the wear during pin-on-disc tests is evaluated. In this sense, the analysis of the surface damage for the different pins will help us to understand the service life and wear evolution of the forging dies. The results show that plasma nitride reduces the friction and prevents the degradation of the pin, independently of the material of the pin, when sliding over finishing and roughing EDM conditions.

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Section: Introductionmentioning

confidence: 99%

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

et al. 2020

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“…c After the machining operation [166] Fig. 25 Defects in dies and moulds that could be repaired by employing hybrid AM solutions [169,170] linear gradient between Fe and Ni was achieved as a result of the good diffusion and the strong bonding between the deposited layers.…”

Section: Functionally Graded Materialsmentioning

confidence: 99%

Powder-based laser hybrid additive manufacturing of metals: a review

Jiménez

Bidare

Hassanin

et al. 2021

Int J Adv Manuf Technol

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Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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“…In case the part made by this tool is not to be phased out, repair, and remanufacture (and reuse) of the tool is of great significant for the operational efficiency. The die stands for 10-30% of the total costs of hot forged components [54], and it is essential to restart the production quickly and economically [52].…”

Section: Tool and Die Repair And Remanufacturementioning

confidence: 99%

“…1. Some of these failure mechanisms require repolishing (or surface cleaning by other methods), thin film surface treatment (CVD, PVD), or surface hardening by laser, nitriding, or boriding [54].…”

Section: Tool and Die Repair And Remanufacturementioning

confidence: 99%

Tool and Die Making, Surface Treatment, and Repair by Laser-based Additive Processes

Asnafi

2021

Berg Huettenmaenn Monatsh

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This paper explores the possibilities to use laser-based additive processes to make, surface treat and repair/remanufacture tools, dies and molds for cold working, hot working, and injection molding. The failures encountered in these applications are described. The materials used conventionally and in the laser additive processes are accounted for. The properties of the tools, dies and molds made by Laser-based Powder Bed Fusion (L-PBF) are as good as and in some cases better than the properties of those made in wrought materials. Shorter cycle time, reduced friction, smaller abrasive wear, and longer life cycle are some of the benefits of L‑PBF and Directed Energy Deposition with powder (DED-p) (or Laser Metal Deposition with powder, LMD‑p, or Laser Cladding, LC). L‑PBF leads to higher toolmaking costs and shorter toolmaking lead time. Based on a review of conducted investigations, this paper shows that it is possible to design and make tools, dies and molds for and by L‑PBF, surface functionalize them by DED-p (LMD‑p, LC), and repair/remanufacture them by DED-p (LMD‑p, LC). With efficient operational performance as the target for the whole tool life cycle, this combination of L‑PBF and DED-p (LMD‑p, LC) has the greatest potential for hot working and injection molding tools and the smallest for cold working tools (due to the current high L‑PBF and DED-p (LMD‑p, LC) costs).

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Damage, Lifetime, and Repair of Forging Dies

Cited by 27 publications

References 5 publications

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

Powder-based laser hybrid additive manufacturing of metals: a review

Tool and Die Making, Surface Treatment, and Repair by Laser-based Additive Processes

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