RESEARCH PAPER
Analysis of the influence of lubrication conditions on tool wear used in hot die forging processes
More details
Hide details
1
Department of Mechanical Engineering Wroclaw University of Science and Technology Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland
2
Kuźnia Jawor S.A. ul. Kuziennicza 4, 59-400 Jawor, Poland
Publication date: 2018-06-30
Eksploatacja i Niezawodność – Maintenance and Reliability 2018;20(2):169-176
KEYWORDS
ABSTRACT
The study discusses the subject of lubrication in the processes of hot die forging with the consideration of the durability of forging
tools and instrumentation. It presents a literature research as well as the authors’ own investigations of the effect of the use of
cooling and lubrication agents, the amount of the dosage as well as the direction of its application, and also the factors influencing
the tribological conditions. The lubrication devices and systems currently applied in the industry have been analyzed as well. On
this basis, making use of their knowledge and experience, the authors have developed and constructed a lubricating device. The
elaborated system, implemented into the industrial process, makes it possible to select and ensure the optimal tribological conditions of the process by way of controlling the amount and frequency of the applied lubricant dosage. It can constitute an alternative
for the manual method of lubricant application, which is dependent on the human factor, or the fully automated, yet expensive,
lubrication systems. The obtained test results point to potential possibilities of a permanent introduction of the constructed device
also into other forging processes, through its integration with a manipulator. The proposed solution ensures more stability and
higher repeatability of the lubrication conditions as well as increases the efficiency of the production process, thus significantly
reducing the unit costs of the production of forgings
REFERENCES (37)
1.
Altan T, Ngaile G, Shen G. Cold and hot forging: fundamentals and applications. ASM International, Ohio 2005.
3.
Anders P, Hogmark S, Bergström J. Simulation and evaluation of thermal fatigue cracking of hot work tool steels. International Journal of Fatigue 2004; (10): 1095-1107.
5.
Bay N. New lubricant systems for cold and warm forging – advantages and limitations. In Liewald, M.: Proceed. 12th Int. Cold Forging Congr., Stuttgart, Germany 2011; 1(8).
6.
Bay N. New Tribo-systems for Cold Forming of Steel, Stainless Steel and Aluminium Alloys. Proceedings of 46th International Cold Forging Group (ICFG) Plenary Meeting 2013.
7.
Berti G A, Monti M. Thermo-mechanical fatigue life assessment of hot forging die steel. Fatigue & Fracture of Engineering Materials & Structures 2005; 28 (11): 1025–1034,
https://doi.org/10.1111/j.1460....
9.
Choi Ch, Groseclose A, Altan T. Estimation of plastic deformation and abrasive wear in warm forging dies. Journal of Materials Processing Technology 2012; 212 (8): 1742–1752,
https://doi.org/10.1016/j.jmat....
10.
Colin S H. A review of automation in manufacturing illustrated by a case study on mixed-mode hot forging. Manufacturing Review 2014; (1)15,
https://doi.org/10.1051/mfrevi....
11.
Daouben E E, et a., Effects of lubricant and lubrication parameters on friction during hot steel forging. International Journal of Material Forming 2008; 1: 1223–1226,
https://doi.org/10.1007/s12289....
12.
Deacon R F, Goodman J K. Spreading Behavior of water based graphite Lubricants on Hot Die Surfaces. CIRP 2006; (55)1: 299-302.
13.
Gronostajski Z, et al. The failure mechanisms of hot forging dies. Materials Science and Engineering, A Structural Materials: Properties, Microstructure and Processing 2016; 657: 147-160,
https://doi.org/10.1016/j.msea....
14.
Gronostajski Z, Hawryluk M, et al. The application of the reverse 3D scanning method to evaluate the wear of forging tools divided on two selected areas. International Journal of Automotive Technology 2017; 18 (4): 653−662,
https://doi.org/10.1007/s12239....
15.
Gronostajski Z, Hawryluk M, Kaszuba M, Ziemba J. Application of a measuring arm with an integrated laser scanner in the analysis of the shape changes of forging instrumentation during production. Eksploatacja i Niezawodnosc – Maintenance and Reliability 2016; 18(2): 194–200,
https://doi.org/10.17531/ein.2....
16.
Hawryluk M, et. al. Systems of supervision and analysis of industrial forging processes. Eksploatacja i Niezawodność - Maintenance and Reliability 2016; 18 (3): 315-324,
https://doi.org/10.17531/ein.2....
17.
Hirschvogel M, Doelen H V. Some applications of cold and warm forging. Journal of Materials Processing Technology 1992; 35 (7): 343-356,
https://doi.org/10.1016/0924-0....
20.
Huskonen W D. Trends in Die Lubrication. Forging Magazine 2004; (10): 24-26.
21.
Isogawa S, Kimura A, Tozawa Y. Proposal of an evaluating method on lubrication. CIRP Annals - Manufacturing Technology 1992; 41: 263-266, 10.1016/S0007-8506(07)61200-1.
23.
Kima D H, Leeb H C, Kimc B M, Kimd K H. Estimation of die service life against plastic deformation and wear during hot forging processes. Journal of Materials Processing Technology 2005; 166: 372–380,
https://doi.org/10.1016/j.jmat....
24.
Kumar U. et al. Hot forging lubricants. International Journal of Mechanical Engineering and Robotics 2014; 3 (4): 155-163.
25.
Lange K, Cser L, Geiger M, Kals J A G. Tool life and tool quality in bulk metal forming. Proceedings of the Institution of Mechanical Engineers. Part B: Journal of Engineering Manufacture November 1993; 207: 223-239,
https://doi.org/10.1243/PIME_P....
26.
Lavtar L, Muhic T, Kugler G, Tercelj M. Analysis of the main types of damage on a pair of industrial dies for hot forging car steering mechanisms. Engineering Failure Analysis 2011; 18 (10): 1143-1152,
https://doi.org/10.1016/j.engf....
27.
Manji J. Die Lubricants, Forging 1994: 39–44.
28.
Nagahama T, Enomae S. Cold- and warm-forging press developments and applications. Journal of Materials Processing Technology 1992; 35(3–4): 415-427,
https://doi.org/10.1016/0924-0....
30.
Persson A, Hogmarkb S, Bergstroma J. Thermal fatigue cracking of surface engineered hot work tool steels. Surface & Coatings Technology 2005; 191: 216– 227,
https://doi.org/10.1016/j.surf....
31.
Sagisaka Y, Ishibashi I, Nakamura T, Sasaoka E, Hayakawa K. Evaluation of Environmentally Friendly Lubricant for Aluminium Alloy Cold Forging. Steel Res. Int., Special Edition, Wiley-VHC Verlag, Weinheim, 2011; 245-248.
32.
Schey J. Tribology in Metalworking: Lubrication. Friction, and Wear American Society for Metals, USA 1983.
33.
Sheljaskow S. Current level of development of warm forging technology. Journal of Materials Processing Technology1994; 46 (7): 3-18,
https://doi.org/10.1016/0924-0....
35.
Soltani M, Pola A, La Vecchia G.M, Modigell M. Numerical method for modelling spray quenching of cylindrical forgings. La Metallurgia Italiana 2015; (7)8 : 33-40.
37.
Taylan A, Gracious N, Gangshu S. Cold and hot forging fundamentals and application. ASM International. Asmmetalshandbook 2005; 14: 337-338.
CITATIONS (6):