Wear analysis of forging tools used in the hot forging processes using 3D reverse scanning techniques and cooling-lubricating system

Hawryluk, Marek; Ziemba, Jacek; Dworzak, Ł.; Kaczyński, Paweł; Kasprzak, Marcin

doi:10.1007/s00170-018-2066-y

Cited by 17 publications

(12 citation statements)

References 26 publications

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“…In order to better visualize the volumetric changes in the subsequent forgings for each variant, the Polyworks software was used to build a graph of the volume changes of the forgings for the entire deformation area identical to the worn area of the die cavity (Fig. 12), according to the 3d scanning revers method-developed by authors [31,34]. Analyzing the gradual (as the number of forgings increased) increase in the volume of material on the forgings indicates the progressing wear (material loss) of each tool.…”

Section: Tests In Industrial Conditionsmentioning

confidence: 99%

“…In [30] the authors developed a lubricating device equipped with a peristaltic pump, which ensured the delivery of a constant dose of lubricant in the front wheel forging process. However, [31,32] describe the use of an improved lubricating and cooling system additionally equipped with an automatic system cleaning system. The system was implemented in an industrial forging process of a forked type forging, which resulted in the tool life being extended by approx.…”

Section: Introductionmentioning

confidence: 99%

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The Impact of the Lubricant Dose on the Reduction of Wear of QRO90 Steel Dies Used in the Forging Process of the Valve Forging Made of High-Nickel Steel

Dworzak¹,

Hawryluk²,

Janik³

2020

Preprint

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TThe paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface, as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings which ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings, for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM. For best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool, up to the maximum service life.

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Section: Tests In Industrial Conditionsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The Impact of the Lubricant Dose on the Reduction of Wear of QRO90 Steel Dies Used in the Forging Process of the Valve Forging Made of High-Nickel Steel

Dworzak¹,

Hawryluk²,

Janik³

2020

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…In [ 30 ], the authors developed a lubricating device equipped with a peristaltic pump, which ensured the delivery of a constant dose of lubricant in the front wheel forging process. However, [ 31 , 32 ] describe the use of an improved lubricating and cooling system additionally equipped with an automatic system cleaning system. The system was implemented in an industrial forging process of a forked type forging, which resulted in the tool life being extended by approximately 20% [ 33 ].…”

Section: Introductionmentioning

confidence: 99%

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

2021

Self Cite

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The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings that ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM (Scanning Electron Microscope). For the best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool up to the maximum service life.

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“…Then, conducting further research including an evaluation of the effect of clearances and dynamic deformations of the press as well as the force distribution during the forging process was made through numerical modeling. However, in a situation where such a typical approach using classical methods of analysis and measurement is insufficient, it is necessary to search for new non-conventional methods, which, so far, have not been applied in solving problems of this kind [ 49 , 50 , 51 ]. One of them may be the approach proposed by the authors, which consists in the use of the indirect measurement method based on measurements of selected geometrical features of the product—a yoke-type die forging, assigned for steering columns for the evaluation of the manufacture correctness of the key press elements (base holders, slide and guides) as well as the forging instrumentation mounted based on SMED.…”

Section: Introductionmentioning

confidence: 99%

Application of 3D Scanning as an Indirect Method to Analyze and Eliminate Errors on the Manufactured Yoke-Type Forgings Forged in SMED Device on Modernized Crank Press

Ziemba

Hawryluk

Rychlik³

2020

Materials

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This article proposes an indirect measurement method based on a dimensional and shape analysis of forgings for the evaluation of the manufacture and the proper operation of the key elements of the crank press, in which after modernization, a quick tool assembly based on SMED (Single Minute Exchange of Die) was implemented. As a result of the introduced changes aiming at improving the forging aggregate and increasing the production efficiency, errors were observed on the manufactured products-forgings in the form of twists and joggles. In order to solve the problem, a lot of advanced methods was used, including: dynamic system of deformation analysis, numerical modeling and as well as dimensional and shape analysis by 3d scanning. Despite the above, this approach (classic way) did not solve the problem. A proprietary method with the use of 3D reverse scanning was proposed, which allows to solve the problem of forgings errors. Based on the measurement results and analyses for a few variants of production cycles, the necessary changes were obtained, making it possible to minimize the errors and obtain proper products in respect of geometry and quality.

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Wear analysis of forging tools used in the hot forging processes using 3D reverse scanning techniques and cooling-lubricating system

Cited by 17 publications

References 26 publications

The Impact of the Lubricant Dose on the Reduction of Wear of QRO90 Steel Dies Used in the Forging Process of the Valve Forging Made of High-Nickel Steel

The Impact of the Lubricant Dose on the Reduction of Wear of QRO90 Steel Dies Used in the Forging Process of the Valve Forging Made of High-Nickel Steel

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

Application of 3D Scanning as an Indirect Method to Analyze and Eliminate Errors on the Manufactured Yoke-Type Forgings Forged in SMED Device on Modernized Crank Press

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