Tool life enhancement in cold forging by locally optimized surfaces

Wagner, K.; Völkl, Ralf; Engel, Ulf

doi:10.1016/j.jmatprotec.2007.11.152

Cited by 43 publications

(16 citation statements)

References 3 publications

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“…Using a strip drawing test experiment, Brinksmeier et al [69] have shown that there is an optimum finish for which friction is the lowest and that a smoother surface finish does not necessarily correlate with less friction. Similar applications in the case of bulk forming have been reported by Geiger et al [70] and Wagner et al [28] where it was shown that proper surface texturing could increase die life.…”

Section: Critical Issues Particular To Microformingsupporting

confidence: 73%

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Tool Wear and Life Span Variations in Cold Forming Operations and Their Implications in Microforming

et al. 2016

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Abstract:The current paper aims to review tooling life span, failure modes and models in cold microforming processes. As there is nearly no information available on tool-life for microforming the starting point was conventional cold forming. In cold forming common failures are (1) over stressing of the tool; (2) abrasive wear; (3) galling or adhesive wear, and (4) fatigue failure. The large variation in tool life observed in production and how to predict this was reviewed as this is important to the viability of microforming based on that the tooling cost takes a higher portion of the part cost. Anisotropic properties of the tool materials affect tool life span and depend on both the as-received and in-service conditions. It was concluded that preconditioning of the tool surface, and coating are important to control wear and fatigue. Properly managed, the detrimental effects from surface particles can be reduced. Under high stress low-cycle fatigue conditions, fatigue failure form internal microstructures and inclusions are common. To improve abrasive wear resistance larger carbides are commonly the solution which will have a negative impact on tooling life as these tend to be the root cause of fatigue failures. This has significant impact on cold microforming.

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Section: Critical Issues Particular To Microformingsupporting

confidence: 73%

“…One reason was the generation of very deep compressive stress [26]. Similarly, surface texturing using lasers have been tested with life extensions up to 170% though improved lubricant retention [27,28].…”

mentioning

confidence: 99%

Tool Wear and Life Span Variations in Cold Forming Operations and Their Implications in Microforming

et al. 2016

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“…Adjustment of the flank angle is achieved by laser texturing with controlled defocusing. With this discovery new production tests resulted in significant extension of the punch life, [206]. Davis et al [43] have tested the influence of textured AISI D2 tool steel surface on friction in strip drawing of AHSS, DP600, at contact pressures ranging from 30-120 MPa.…”

Section: Surface Textured Cold Forging Toolsmentioning

confidence: 99%

Environmentally benign tribo-systems for metal forming

et al. 2010

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The growing awareness of environmental issues and the requirements to establish solutions diminishing the impact on working environment as well as external environment has initiated ever increasing efforts to develop new, environmentally benign tribological systems for metal forming. The present paper gives an overview of these efforts substituting environmentally hazardous lubricants in cold, warm and hot forging as well as sheet forming and punching/blanking by new, less harmful lubricants and furthermore describes other more generic measures directed towards the same goal such as development of anti-seizure tool materials and coatings and application of structured workpiece and tool surfaces.

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“…Micro-texturing of functional tool surfaces can help reduce friction and wear during critical forming processes like cold forging (Wagner et al, 2006 and, sheet rolling (Ike et al, 2002), deep drawing (Vermeulen and Scheers, 2001). This increases tool life and reduces the amount of consumed lubricants.…”

Section: Application Of Surface Texturing In Tribologymentioning

confidence: 99%

Optimised textured surfaces with application in piston ring/cylinder liner contact

Rahmani

Shirvani

2010

Tribology and Dynamics of Engine and Powertrain

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This item was submitted to Loughborough's Institutional Repository (https://dspace.lboro.ac.uk/) by the author and is made available under the following Creative Commons Licence conditions.For the full text of this licence, please go to: http://creativecommons.org/licenses/by-nc-nd/2.5/ In: Tribology and Dynamics of Engine and Powertrain: Fundamentals, Applications and Future Trends, Edited by H. Rahnejat, Woodhead Publishing, 2010, pp. 470-517, ISBN: 978-1-84569-993-2 Chapter 14 Optimised Textured Surfaces with Application in Piston-Ring/Cylinder Liner Contact R. RAHMANI, Loughborough University, UK A. SHIRVANI and H. SHIRVANI, Anglia Ruskin University, UK Abstract: The application of textured surfaces in tribology has recently gained a huge momentum. In this chapter, a systematic approach to investigate the maximum outcomes from employing such surfaces is introduced with an insight into their application in internal combustion engines. A combination of various affecting parameters on the tribological performance of such surfaces is studied and the optimum results were introduced. The effect of employing such optimised textures in enhancing the lubrication condition in piston ring/cylinder liner contact is also studied.Key words: surface texturing, piston ring/cylinder liner contact, optimisation, slider bearings IntroductionIn general, friction is inherent to and is produced between bodies in contact with relative motion. Friction tends to oppose this relative motion between the bodies through loss of energy mostly in the form of heat, mechanical vibration and noise. Therefore, in most cases, friction is an unfavourable phenomenon. In some cases introduction of friction is desired, for example in order to slow down a moving car, the brakes are used to reduce the existing kinetic energy in the wheels by means of producing frictional losses. However, in most of the cases, facilitating this relative motion between bodies is of concern and as a result, one needs to overcome friction so that the relative motion pursues with a minimal loss of energy.Excessive friction can cause damage to the surfaces in contact in several ways and as a result make them wear. Since the surfaces are damaged due to wear, the rate of energy dissipation due to friction increases and consequently amplifies the rate of wear itself (see Chapter 2).The reason for the existence of friction is mainly that in reality, there is no perfect smooth surface. In fact, surfaces have a degree of roughness in the form of small 'hills' and 'valleys' no matter how well they are prepared. When two surfaces, which are in contact with each other, are put into relative motion, the asperities on the In: Tribology and Dynamics of Engine and Powertrain: Fundamentals, Applications and Future Trends, Edited by H. Rahnejat, Woodhead Publishing, 2010, pp. 470-517, ISBN: 978-1-84569-993-2 opposing surfaces become locked hence inducing friction as initially proposed by Amontons for onset of motion and later under kinetic conditions by Coulomb (see Chapter 2). W...

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Tool life enhancement in cold forging by locally optimized surfaces

Cited by 43 publications

References 3 publications

Tool Wear and Life Span Variations in Cold Forming Operations and Their Implications in Microforming

Tool Wear and Life Span Variations in Cold Forming Operations and Their Implications in Microforming

Environmentally benign tribo-systems for metal forming

Optimised textured surfaces with application in piston ring/cylinder liner contact

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