Development of Ceramic Inserts for Forging Tools

Kwon, Hyuk-Hong; Bramely, Alan N.

doi:10.1016/s0007-8506(07)62922-9

Cited by 7 publications

(5 citation statements)

References 4 publications

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“…For example, previous investigations of hybrid-forging dies were often carried out with wear-resistant die inserts. Kwon et al [9] developed ceramic zirconia inserts that were thermally shrunk into forging dies and could withstand high thermal and mechanical loads. No cooling channels were present in these inserts and yet increased wear resistance could be achieved as a result.…”

Section: State Of the Artmentioning

confidence: 99%

“…No cooling channels were present in these inserts and yet increased wear resistance could be achieved as a result. However, ceramic inserts feature a low ductility and are prone to material breakouts [9]. Another approach deals with the application of cooling channels.…”

Section: State Of the Artmentioning

confidence: 99%

“…For the field of injection moulding, different approaches are extensively presented [12]. In the context of the work of Kwon et al [9], a suitable geometry with parameter combination for the cooling channel within the process of injection moulding was calculated by means of a mathematical optimisation. The focus was on optimised heat dissipation.…”

Section: State Of the Artmentioning

confidence: 99%

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Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

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Internal die cooling during forging can reduce thermal loads, counteracting surface softening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel’s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.

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Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

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Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

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show abstract

“…The application of ceramic inserts joint by active brazing in regions with high wear is a promising solution in order to reduce wear [2,6]. The application of ceramic inserts joint by active brazing in regions with high wear is a promising solution in order to reduce wear [2,6].…”

Section: Precison Forging Using a Conventional Diementioning

confidence: 99%

“…In many cases dies for forging of axially symmetric forgings are considered for the application of ceramics [5,6]. A stress analysis considering shrinking and forging process is necessary in order to optimize the die design [6]. A stress analysis considering shrinking and forging process is necessary in order to optimize the die design [6].…”

Section: Introductionmentioning

confidence: 99%

Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis

Behrens¹,

Schaefer²,

Bistron³

2007

AIP Conference Proceedings

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A finite-element-analysis of orthogonal metal cutting processes AIP Conf.Abstract. The tools in hot forging processes are exposed to high thermal and mechanical loadings. Tempering of the tool edge layer occurs as a result of thermal loadings. This leads to a gradual hardness loss of the tool material and increase of wear over forging cycles. Hence, the tool life in hot forging is mainly limited by wear. An extension of the die service life can be achieved by the use of ceramic inserts. The integration of ceramics into the die base plate made of hot-work steel is realised by active brazing, whereby it possible to apply ceramic in region with high wear. It has to be ensured in the design process of ceramic inserts for forging dies that no critical tensile stresses occur in the ceramics. A reliable design of the ceramic inserts is possible only through consideration of brazing and forming process. The development of a Finite-Element-model for the design of forging dies with ceramic inserts is the intention of the work presented in this paper. At first the forging process with a conventional die is analyzed concerning abrasive die wear to identify regions with high wear risk applying a modified Archard model. Based on the results of wear calculation, a forging die with ceramic inserts is investigated in terms of joint stresses at the end of the active brazing process. Subsequently, the forging process considering the residual stresses caused by joining is simulated in order to obtain the die stress in use.

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Investigation of applying protective sheet metal die covers for hot forging dies on a cross-forging geometry

Zottis

Wolfgarten

2019

Int J Adv Manuf Technol

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Development of Ceramic Inserts for Forging Tools

Cited by 7 publications

References 4 publications

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis

Investigation of applying protective sheet metal die covers for hot forging dies on a cross-forging geometry

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