Numerical Investigation for the Design of a Hot Forging Die with Integrated Cooling Channels

Behrens, Bernd‐Arno; Bouguecha, Anas; Vucetic, Milan; Bonhage, Martin; Malik, I.

doi:10.1016/j.protcy.2016.08.008

Cited by 13 publications

(5 citation statements)

References 8 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…This cooling concept is state of the art for injection moulding but is challenging in die forging due to high mechanical die loads [10]. Accordingly, there are currently only initial approaches to the use of internal cooling channels in hot-forging dies, such as in the work of Behrens et al [11]. In their work, two different approaches to the use of the channels were designed and numerically investigated.…”

Section: State Of the Artmentioning

confidence: 99%

“…The research in the comprehensive review paper by Feng et al [12] makes it clear that almost no research has been done on internal cooling channels in the field of hot forging. Only the work of Behrens et al [11] is cited for this application area. For the field of injection moulding, different approaches are extensively presented [12].…”

Section: State Of the Artmentioning

confidence: 99%

See 1 more Smart Citation

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

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

View full text Add to dashboard Cite

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.

show abstract

Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

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

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

View full text Add to dashboard Cite

show abstract

“…Out of injection moulding process, there are some other forming processes which are using cooling channels such as in the study performed by Behrens et al [28]. Cooling channel development for hot forging process was studied by Behrens et al.…”

Section: Seal Seat Spigotmentioning

confidence: 99%

Development of a Cooling Die Used in Plastic Pipe Processing: Numerical and Experimental Analysis

Gemici¹

2018

Journal of Thermal Engineering

View full text Add to dashboard Cite

In this study, cooling of a plastic pipe-end during a hot-forming process that is one of the commonly used forming methods in plastic pipe production to get seal housing place (muff) was investigated numerically and experimentally. The aim of this study was development of a cooling die that has higher cooling performance and easier manufacturability. Cooling is supplied by the circulation of conditioned water in the channels located in the die in plastic production. The geometry of these channels and mass flow rate and temperature of the cooling water are the parameters affecting the quality of the formed region and process time. In the study, experimental analyses were performed, then numerical analyses were realised and validated with the experimental results for the existing die geometry. Continuity, momentum and energy equations were solved all together and heat transfer was investigated. After validating the model, a few different alternative die models were proposed and analysed to get an optimum which has highest cooling capacity and process ability. At the end of these studies, optimum alternative die geometry was determined. The channels in the suggested die were developed to increase the homogeneity of the cooling by changing the existing channel's shape which can be produced by only longitudinal holes. A simple production method was also suggested for the new die to locate the channels following the circumference of the pipe, like conformal cooling channels. Additionally, aluminium material was also used to decrease the pipe temperature and die weight in the analyses. In conclusion, although cooling process time and mean temperature of the pipe-end were 30 secs and 43.9 o C respectively for the existing cooling die, these values were determined as 30 secs and 39.5 o C for the optimised aluminium die. If the temperature of the cooled pipe is taken as the same with the existing cooling, the cooling time decreases to around 20 secs for the suggested die. The weight of the die was reduced from 86.57 kg to 16.22 kg.

show abstract

“…Therefore, semifinished parts are heated above 1000 • C and, for example, formed in a forging die [1]. In service, the hot forging tools are exposed to high cyclic mechanical and thermal loading conditions in addition to wear [2]. Although the temperature inside the tools is almost constant over the forming cycle after run-in of the tools [3], contact with the billet during forming and cooling of the hot work tools after each forging step results in high mechanically induced stresses as well as in thermally induced stresses due to the sharp temperature gradients in near-surface regions.…”

Section: Introductionmentioning

confidence: 99%

A Temperature-Dependent Viscoplasticity Model for the Hot Work Steel X38CrMoV5-3, Including Thermal and Cyclic Softening under Thermomechanical Fatigue Loading

2023

View full text Add to dashboard Cite

In this paper, a temperature-dependent viscoplasticity model is presented that describes thermal and cyclic softening of the hot work steel X38CrMoV5-3 under thermomechanical fatigue loading. The model describes the softening state of the material by evolution equations, the material properties of which can be determined on the basis of a defined experimental program. A kinetic model is employed to capture the effect of coarsening carbides and a new isotropic cyclic softening model is developed that takes history effects during thermomechanical loadings into account. The temperature-dependent material properties of the viscoplasticity model are determined on the basis of experimental data measured in isothermal and thermomechanical fatigue tests for the material X38CrMoV5-3 in the temperature range between 20 and 650 ∘C. The comparison of the model and an existing model for isotropic softening shows an improved description of the softening behavior under thermomechanical fatigue loading. A good overall description of the experimental data is possible with the presented viscoplasticity model, so that it is suited for the assessment of operating loads of hot forging tools.

show abstract

Numerical Investigation for the Design of a Hot Forging Die with Integrated Cooling Channels

Cited by 13 publications

References 8 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

Development of a Cooling Die Used in Plastic Pipe Processing: Numerical and Experimental Analysis

A Temperature-Dependent Viscoplasticity Model for the Hot Work Steel X38CrMoV5-3, Including Thermal and Cyclic Softening under Thermomechanical Fatigue Loading

Contact Info

Product

Resources

About