A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out. The various models available for abrasive wear such as Archard, Felder-Montagut and IFUM model and for adhesive wear such as Holms model has been studied and implemented in commercial FE Code by developing FORTRAN subroutine and wear is calculated and visualized for different phenomenological models. Die wear is simulated in actual shop floor by carrying out continuous forging and the dies were scanned in post forging condition for its 3D profile leading to exact quantification of the wear. The results obtained from calculations are compared with the shop floor measurements. The abrasive wear is found to be prominent wear mode and as a part of this research a suitable approach to predict the die life based on geometrical tolerances is suggested. The predicted results showed good correlation with the experimental results.