Fatigue life prediction model of WC-Co cold forging dies based on experimental and numerical studies

Tanrıkulu, Barış; Karakuzu, Ramazan

doi:10.1016/j.engfailanal.2020.104910

Cited by 11 publications

(14 citation statements)

References 19 publications

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“…The flow stresses thus derived are acceptable and can be used to evaluate the cold forgeability of high-strength materials, such as stainless steel and ESW material, which exhibit high-level strain-hardening. The predicted die fatigue lives are compared in Figure 13a, which were calculated using the die fatigue properties presented by Tanikulu and Karakuzu [18]. The comparison shows that non-isothermal analysis facilitates process design, while isothermal analysis does not.…”

Section: Fea Predictions and Experimental Data For Automatic Multi-stage Cold Forging Of An Sus304 Ball-studmentioning

confidence: 99%

“…The predicted die fatigue lives are compared in Figure 13 a, which were calculated using the die fatigue properties presented by Tanikulu and Karakuzu [ 18 ]. The comparison shows that non-isothermal analysis facilitates process design, while isothermal analysis does not.…”

Section: Fea Predictions and Experimental Data For Automatic Multmentioning

confidence: 99%

“…For the ESW materials [7], the Bauschinger effect reduces die stress by 8%, and also lowers the forming load; these must not be neglected during the cold forging of high-strength materials because die fatigue life decreases exponentially as die stress increases. For example, a 6% reduction in die stress from 850 MPa at a stress ratio R = 0.1 of 20% WC-Co 20% [18] increases the fatigue life by about 72% from the initial 39,000 cycles. Cold forging of high-strength materials is characterized by relatively high global heating that is locally intense in the major deformation region, because over 90% of energy consumption is dissipated as thermal energy (via viscous heating).…”

Section: Introductionmentioning

confidence: 99%

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Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Byun

Razali

Lee³

et al. 2020

Materials

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SUS304 stainless steel is characterized by combined tensile and compression testing, with an emphasis on flow stress at higher strain and temperature. The plastic deformation behavior of SUS304 from room temperature to 400 °C is examined and a general approach is used to express flow stress as a closed-form function of strain, strain rate, and temperature; this is optimal when the strain is high, especially during automatic multi-stage cold forging. The fitted flow stress is subjected to elastothermoviscoplastic finite element analysis (FEA) of an automatic multi-stage cold forging process for an SUS304 ball-stud. The importance of the thermal effect during cold forging, in terms of high material strength and good strain-hardening, is revealed by comparing the forming load, die wear and die stress predictions of non-isothermal and isothermal FEAs. The experiments have shown that the predictions of isothermal FEA are not feasible because of the high predicted effective stress on the weakest part of the die.

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Section: Fea Predictions and Experimental Data For Automatic Multi-stage Cold Forging Of An Sus304 Ball-studmentioning

confidence: 99%

Section: Fea Predictions and Experimental Data For Automatic Multmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Byun

Razali

Lee³

et al. 2020

Materials

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“…Low-cycle fatigue (LCF) in metal forming is deeply related to die life during hot metal forming [ 1 ]. To the contrary, the high-cycle fatigue (HCF) life of die parts is of great importance in cold forging [ 2 ], especially during automatic multi-stage cold forging. Die fatigue life is becoming a major issue because complicated die structural analysis has become increasingly possible owing to recent advances in metal forming simulation technologies [ 3 , 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

“…Wang et al [ 21 ] used an experimental “master fatigue limit diagram” of the die insert material SKD11 [ 22 ] to calculate an optimized shrink-fitting ratio for a two-layer compound die in backward extrusion. Tanrikulu and Karakuzu [ 2 ] performed experimental and numerical studies to predict quantitatively the fatigue life of a WC-Co20% cold forging die using an improved Goodman–Haigh diagram and the Basquin law [ 23 ].…”

Section: Introductionmentioning

confidence: 99%

A New General Fatigue Limit Diagram and Its Application of Predicting Die Fatigue Life during Cold Forging

Joun

Chung

et al. 2022

Materials

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Traditional fatigue fracture theory and practice focus principally on structural design. It is thus too conservative and inappropriate when used to predict the high-cycle fatigue life of dies used for metal forming, especially cold forging. We propose a novel mean stress correction model and diagram to predict the high-cycle fatigue lives of cold forging dies, which focuses on the upper part of the equivalent fatigue strength curve. Considering the features of die materials characterized by high yield strength and low ductility, a straight line is assumed for the tensile yield line. To the contrary, a general curve is used to represent the fatigue strength. They are interpolated, based on the distance ratio, when finding an appropriate equivalent fatigue strength curve at the mean stress and stress amplitude between the line and curve. The approach is applied to a well-defined literature example to verify its validity and shed light on the characteristics of die fatigue life. The approach is also applied to practical forging and useful qualitative results are obtained.

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A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

Sharma

Gupta

et al. 2023

steel research int.

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Forging is a primary manufacturing process used in several manufacturing industries. Aircraft and automobile industries are manufacturing products with high‐dimensional accuracy and quality that are highly precise or near the required shape. Customers require products that are free of cracks and fulfill their functional requirements. This leads to the advancement of the forging process due to its ability to form complicated and intricate shapes. Herein, a detailed review of the aspects of forging is given in which the optimization of factors like preform design, forging conditions, workpiece dimensions, die design, lubricant properties, and thermal treatment parameters are discussed, enhancing the tool life and forging quality of the product. The selection of die‐forging tool material and methods for enhancing the surface quality of forged products are also reviewed. The article also presents methods for measurement of forging quality, tool life, machine effectiveness, forging image acquisition, and forging parameters, which can significantly reduce the risk of error at every step of the forging process. This review serves as a reference for researchers to increase production rate, enhance the effectiveness of measurement system, and improve the quality of forged products with technological advancement.

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Fatigue life prediction model of WC-Co cold forging dies based on experimental and numerical studies

Cited by 11 publications

References 19 publications

Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

A New General Fatigue Limit Diagram and Its Application of Predicting Die Fatigue Life during Cold Forging

A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

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