Evaluation of sheet metal covers to improve tool life in forging

评估金属板覆盖层以提高锻造工具寿命

基本信息

项目摘要

This research project within the German Brazilian research cooperation BRAGECRIM proposes a new method for wear protection in closed die forging using exchangeable sheet metal die covers. The aim of this project is the development of an inexpensive and easily exchangeable sheet metal die cover which is used to protect the engraving. Generally, the results of the first funding period proved that the proposed concept of die cover can be applied to reduce the tool wear and increase the die lifetime in closed-die forging. For an example geometry, the maximum thermal shock was reduced by 140 K and the main principal stress by 10% due to a reduction of the notch effect in the radius of the die. Based upon a die lifetime calculation, an increase of the die lifetime by more than 200% can be expected. Furthermore, in the first funding period, a FEM model was developed, which can realistically predict the material flow of the billet and the behavior of the die cover. The model was validated for different die geometries by forging experiments. Besides these positive results, the first funding period revealed problems like thinning and wrinkling which lead to a destruction of the die cover after just a small number of forging cycles. Both numerical and experimental investigation allowed to analyze the mechanisms for the observed phenomena. The wrinkling and thinning of the die cover are mainly caused by tensile stresses within the sheet resulting from different friction coefficients at the contact between billet and die cover, respectively, die cover and die. Furthermore, the first funding period focused on the investigation of simple die geometries involving strip-like die covers which do not have a self-stiffening 3D curvature. Related work has shown that these self-stiffening effects provide a realistic opportunity to overcome these problems. Therefore, in close cooperation with the Brazilian partner institute LdTM the main focus of the second funding period is put on the analysis of boundary conditions, die geometries and process chains, where the limitations observed in the first funding period do not prevent a successful application of the die cover concept. To eliminate the tensile stresses within the sheet, the influence of different friction coefficients at both contact surfaces will be investigated. In addition, an enhanced fixation of the sheet within the die will be tested in order to prevent a relative movement between the die cover and the forging die. Besides this variation of the boundary conditions, a second main aim will be the investigation of 3D die covers geometries offering a larger stiffness to reduce the undesired effects considerably. After the second funding period, the concept shall be progressed to a point where a transfer to industrial application is realistic. It is planned to cooperate with ThyssenKrupp Metalúrgica Campo Limpo Ltda.
德国巴西研究合作机构BRAGECRIM的这一研究项目提出了一种新的方法,使用可更换的金属板模盖在闭式模锻中进行磨损保护。该项目的目的是开发一种廉价且易于更换的金属板模具盖,用于保护雕刻。总的来说,第一个资助期的结果证明,所提出的模具盖的概念可以应用于减少模具磨损和增加模具寿命在闭式模锻。对于一个示例的几何形状,最大热冲击减少了140 K和主要的主应力减少了10%,由于减少了凹口效应的半径的模具。根据模具寿命计算,可以预期模具寿命增加200%以上。此外,在第一个资助期,开发了一个有限元模型,可以真实地预测坯料的材料流动和模具盖的行为。通过锻造实验验证了该模型在不同模具几何形状下的有效性。除了这些积极的结果外,第一个资助期还发现了一些问题,如减薄和磨损,这些问题导致模具盖在少量锻造循环后损坏。数值和实验研究允许分析所观察到的现象的机制。模盖的起皱和变薄主要是由于坯料与模盖、模盖与模具之间的接触处的不同摩擦系数导致的板料内的拉应力引起的。此外,第一个资助期的重点是研究简单的模具几何形状,包括带状模具盖,没有自加强的3D曲率。相关研究表明,这些自硬化效应为克服这些问题提供了现实的机会。因此,在与巴西合作伙伴研究所LdTM的密切合作下,第二个资助期的主要重点放在边界条件、模具几何形状和工艺链的分析上,其中第一个资助期观察到的局限性并不妨碍模盖概念的成功应用。为了消除板内的拉应力,将研究两个接触表面处不同摩擦系数的影响。此外,将测试板在模具内的增强固定,以防止模具盖和锻造模具之间的相对移动。除了边界条件的这种变化之外,第二个主要目标将是研究3D模具盖几何形状,其提供更大的刚度以显著减少不期望的影响。在第二个供资期之后,这一概念将逐步发展到能够实际转入工业应用的程度。计划与ThyssenKrupp Metalúrgica Campo Limpo Ltda合作。

项目成果

期刊论文数量(4)
专著数量(0)
科研奖励数量(0)
会议论文数量(0)
专利数量(0)
Experimental evaluation of wear protection ability of sheet metal die covers in closed-die forging
  • DOI:
    10.1007/s11740-019-00917-z
  • 发表时间:
    2019-08
  • 期刊:
  • 影响因子:
    0
  • 作者:
    Yingyan Yu;D. R. Alba;L. Schaeffer;G. Hirt
  • 通讯作者:
    Yingyan Yu;D. R. Alba;L. Schaeffer;G. Hirt
Investigation of applying protective sheet metal die covers for hot forging dies on a cross-forging geometry
在交叉锻造几何形状上应用热锻模具保护性金属板模具盖的研究
First Experimental and Numerical Study on the Use of Sheet Metal Die Covers for Wear Protection in Closed-Die Forging
在闭式模锻中使用金属板模盖进行磨损防护的首次实验和数值研究
  • DOI:
    10.4028/www.scientific.net/kem.651-653.266
  • 发表时间:
    2015
  • 期刊:
  • 影响因子:
    0
  • 作者:
    D. Rosenstock;E.T. Segebade;G. Hirt
  • 通讯作者:
    G. Hirt
Study of the applicability of 22MnB5 sheet metal as protective masks to improve tool life in hot forging process
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Professor Dr.-Ing. Gerhard Hirt其他文献

Professor Dr.-Ing. Gerhard Hirt的其他文献

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{{ truncateString('Professor Dr.-Ing. Gerhard Hirt', 18)}}的其他基金

Investigation of flexible radial ring rolling for production of non-axially symmetric seamless rings on radial axial ring rolling mills
在径向轴向环件轧机上生产非轴对称无缝环的柔性径向环件轧制研究
  • 批准号:
    454751242
  • 财政年份:
    2021
  • 资助金额:
    --
  • 项目类别:
    Research Grants
Characterization of the suitability of high manganese steels for the production of small sheet metal parts by multi-stage deep drawing
高锰钢多级拉深生产小型钣金零件的适用性表征
  • 批准号:
    423190740
  • 财政年份:
    2019
  • 资助金额:
    --
  • 项目类别:
    Research Grants (Transfer Project)
Defined adjustment of the residual stress distribution in strip and sheet material via roller levelling
通过辊矫平对带材和板材中的残余应力分布进行明确的调整
  • 批准号:
    322638998
  • 财政年份:
    2017
  • 资助金额:
    --
  • 项目类别:
    Research Grants (Transfer Project)
Criteria for the closure and pressure welding of pores in open die forging
开式模锻气孔封闭和压焊标准
  • 批准号:
    283878720
  • 财政年份:
    2016
  • 资助金额:
    --
  • 项目类别:
    Research Grants
Model-based description of bond formation, evolution and failure in multi-pass roll bonding processes
基于模型的多道辊压粘合过程中粘合形成、演变和失效的描述
  • 批准号:
    317614920
  • 财政年份:
    2016
  • 资助金额:
    --
  • 项目类别:
    Research Grants (Transfer Project)
Twin-Roll Strip Casting Process for the Production of Clad Strip - Twin-Roll Clad Casting
用于生产复合带材的双辊带材连铸工艺 - 双辊复合连铸
  • 批准号:
    258106764
  • 财政年份:
    2014
  • 资助金额:
    --
  • 项目类别:
    Research Grants
Approach to application-oriented properties of electrical steels by means of cold rolling and heat treatment
通过冷轧和热处理提高电工钢应用性能的方法
  • 批准号:
    255707264
  • 财政年份:
    2014
  • 资助金额:
    --
  • 项目类别:
    Research Units
Increasing the range of producible geometries in open-die forging through superimposed stress states
通过叠加应力状态增加开式模锻可生产的几何形状范围
  • 批准号:
    256896401
  • 财政年份:
    2014
  • 资助金额:
    --
  • 项目类别:
    Research Grants
Lubricant-free tribology concepts for cold extrusion by interaction-reduced coatings and structures
通过减少相互作用的涂层和结构进行冷挤压的无润滑摩擦学概念
  • 批准号:
    244932637
  • 财政年份:
    2013
  • 资助金额:
    --
  • 项目类别:
    Priority Programmes
Analysis of Process Control of Roller Leveling by Utilization of a FE Model with Integrated Closed-loop Control Structures
利用集成闭环控制结构的有限元模型分析辊式矫平过程控制
  • 批准号:
    238040321
  • 财政年份:
    2013
  • 资助金额:
    --
  • 项目类别:
    Research Grants

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