Analysis of the influence of lubrication conditions on tool wear used in hot die forging processes

• Autorzy: Hawryluk M. , Gronostajski Z. , Ziemba J. , Dworzak Ł. , Jabłoński P. , Rychlik M.

Identyfikatory

DOI

10.17531/ein.2018.2.01

Warianty tytułu

PL

Analiza wpływu warunków smarowania na zużycie narzędzi w procesach kucia matrycowego na gorąco

• Języki publikacji: EN PL

Abstrakty

EN

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.

PL

Praca dotyczy problematyki smarowania w procesach kucia matrycowego na gorąco z uwzględnieniem trwałości narzędzi i oprzyrządowania kuźniczego. Przedstawiono badania literaturowe oraz własne autorów dotyczące wpływu zastosowania środków smarno-chłodzących, ilości dawki i kierunku jej podawania oraz innych czynników wpływających na warunki tribologiczne. Przeanalizowano także obecnie stosowane w przemyśle urządzenie i systemy smarowania. Na tej podstawie autorzy w oparciu o wiedzę i doświadczenie opracowali i zbudowali urządzenie smarujące. Opracowany system, zaimplementowany do przemysłowego procesu pozwala na dobór i zapewnienie optymalnych warunków tribologicznych w procesie poprzez sterowanie ilością i częstotliwością podawanej dawki środka smarnego. Może być ono alternatywą dla manualnej metody nanoszenia środka smarnego, zależnej od czynnika ludzkiego lub w pełni zautomatyzowanych, lecz drogich systemów smarowania. Uzyskane wyniki badań wskazują na potencjalne możliwości wprowadzenia na stałe do pracy zbudowanego urządzenia także do innych procesów kucia poprzez integrację z manipulatorem. Zaproponowane rozwiązanie zapewnia większą stabilność i powtarzalność warunków smarowania oraz pozytywnie wpływa na zwiększenie wydajności procesu wytwarzania, a tym samym znacząco obniża jednostkowe koszty produkcji odkuwek.

Słowa kluczowe

EN

hot die forging; lubricating system; wear; tribological conditions

PL

kucie matrycowe na gorąco; system smarujący; zużycie; warunki tribologiczne

• Wydawca: Polskie Naukowo-Techniczne Towarzystwo Eksploatacyjne
• Czasopismo: Eksploatacja i Niezawodność
• Rocznik: 2018
• Tom: Vol. 20, no. 2
• Strony: 169--176
• Opis fizyczny: Bibliogr. 37 poz., rys., tab.

Twórcy

autor

Hawryluk M.

• Department of Mechanical Engineering Wroclaw University of Science and Technology Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland

autor

Gronostajski Z.

• Department of Mechanical Engineering Wroclaw University of Science and Technology Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland

autor

Ziemba J.

• Department of Mechanical Engineering Wroclaw University of Science and Technology Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland

autor

Dworzak Ł.

• Department of Mechanical Engineering Wroclaw University of Science and Technology Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland

autor

Jabłoński P.

• Department of Mechanical Engineering Wroclaw University of Science and Technology Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland

autor

Rychlik M.

• Kuźnia Jawor S.A. ul. Kuziennicza 4, 59-400 Jawor, Poland

Bibliografia

• 1. Altan T, Ngaile G, Shen G. Cold and hot forging: fundamentals and applications. ASM International, Ohio 2005.
• 2. Altan T, Shirgaokar M. Advanced die materials and lubrication systems to reduce die wear in hot and warm forging. https://www.forging.org/uploaded/content/media/AltansPres.pdf
• 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.
• 4. Archard J F. Contact and rubbing of flat surfaces. Journal of Applied Physics 1953; (24): 981-988, https://doi.org/10.1063/1.1721448.
• 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.1460-2695.2005.00940.x.
• 8. Buchmayr B. Damage, Lifetime, and Repair of Forging Dies. BHM Berg- und Hüttenmännische Monatshefte 2017; 162 (3): 88–93, https://doi.org/10.1007/s00501-016-0566-3.
• 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.jmatprotec.2012.03.023.
• 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/mfreview/2014012.
• 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/s12289-008-0162-5.
• 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.2016.01.030.
• 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/s12239-017-0065-x.
• 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.2016.2.6.
• 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.2016.3.1.
• 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/10.1016/0924-0136(92)90326-N.
• 18. https://www.aed-automation.com/en/products/solutions-forging.html, Aed Automation. Solutions forging. 2017. (accessed 17.11.02).
• 19. https://www.jerko-kempen.de, Jerko. 2017. (accessed 17.11.02).
• 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.
• 22. Iwama T, Morimoto Y. Die life and lubrication in warm forging. Journal of Materials Processing Technology 1997; 71: 43-48, https://doi.org/10.1016/S0924-0136(97)00141-6.
• 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.jmatprotec.2004.07.103.
• 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_PROC_1993_207_085_02.
• 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.engfailanal.2010.11.002.
• 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/10.1016/0924-0136(92)90331-L.
• 29. Ngaile G, Saiki H, Ruan L, Marumo Y. A tribo-testing method for high performance cold forging lubricants. Wear 2007; 262:684-692, https://doi.org/10.1016/j.wear.2006.08.009.
• 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.surfcoat.2004.04.053.
• 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/10.1016/0924-0136(94)90099-X.
• 34. Sheljaskow S. Tool lubricating systems in warm forging. Journal of Materials Processing Technology 2001; 113 (1–3): 16-21, https://doi.org/10.1016/S0924-0136(01)00645-8.
• 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.
• 36. Starlinga C, Brancob J. Thermal fatigue of hot work tool steel with hard coatings. Thin Solid Films 1997; 308(309): 436–442, https://doi.org/10.1016/S0040-6090(97)00600-7.
• 37. Taylan A, Gracious N, Gangshu S. Cold and hot forging fundamentals and application. ASM International. Asmmetalshandbook 2005; 14: 337-338.

Uwagi

Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2018).