Material adapted tool design in cold forging exemplified by powder metallurgical tool steels and industrial ceramics

Abstract

The advantages of today's cold forging technology, such as excellent mechanical properties of the workpiece and minimum waste of material together with energy saving via near net shaping increase its competitiveness against other production methods. However, as a result of extremely high loading of the tools when compared with warm and hot forging, tool life is distinctly more confined resulting in increased production costs. Due to separately or concurrently emerging damaging mechanisms of fatigue and wear at different sections of a cold forging die, process specific tool material selection and design of cold forging dies play a decisive role in near-netshape forging of various parts. Two case studies utilizing powder metallurgical tool steel and ceramic as tool materials are presented in this paper. Successful adaptation of these materials with the help of FE simulations led to increased tool life and workpiece quality.

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

“…In cold forging, wear of tools is very high in comparison to warm and hot forging so die material is an important aspect to be considered for tool life improvement. Geiger et al [ 129 ] did a case study on application of ceramic coating (Si 3 N 4 ) on stainless steel. It was observed that with increase in forging load, the ceramic coating had developed cracks due to concentration of tensile strains.…”

Effect of Lubrication and Forging Load on Surface Roughness, Residual Stress, and Deformation of Cold Forging Tools

“…There are many advantages of cold forging, such as excellent mechanical properties of the forged part, minimum material wastage, and the ability to forge a net shape or near-net shape product. However, the cold forging tools are subjected to a combination of abrasive wear and very high mechanical loads, which generates a surface pressure of up to 3000 MPa that is caused by high flow stress of the billet material at room temperature [2,3]. Overstressing of the tool, abrasive wear, galling or adhesive wear, and fatigue failure are common failure modes of cold forging tools [4].…”