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Title: Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis

Abstract

The tools in hot forging processes are exposed to high thermal and mechanical loadings. Tempering of the tool edge layer occurs as a result of thermal loadings. This leads to a gradual hardness loss of the tool material and increase of wear over forging cycles. Hence, the tool life in hot forging is mainly limited by wear. An extension of the die service life can be achieved by the use of ceramic inserts. The integration of ceramics into the die base plate made of hot-work steel is realised by active brazing, whereby it possible to apply ceramic in region with high wear. It has to be ensured in the design process of ceramic inserts for forging dies that no critical tensile stresses occur in the ceramics. A reliable design of the ceramic inserts is possible only through consideration of brazing and forming process. The development of a Finite-Element-model for the design of forging dies with ceramic inserts is the intention of the work presented in this paper. At first the forging process with a conventional die is analyzed concerning abrasive die wear to identify regions with high wear risk applying a modified Archard model. Based on the results of wearmore » calculation, a forging die with ceramic inserts is investigated in terms of joint stresses at the end of the active brazing process. Subsequently, the forging process considering the residual stresses caused by joining is simulated in order to obtain the die stress in use.« less

Authors:
; ;  [1]
  1. Institute of Metal Forming and Metal-Forming Machines, Leibniz University of Hannover, An der Universitaet 2, 30823 Garbsen (Germany)
Publication Date:
OSTI Identifier:
21061787
Resource Type:
Journal Article
Journal Name:
AIP Conference Proceedings
Additional Journal Information:
Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM 2007: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740941; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA); Journal ID: ISSN 0094-243X
Country of Publication:
United States
Language:
English
Subject:
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS; ABRASIVES; BRAZING; CERAMICS; COMPUTERIZED SIMULATION; FINITE ELEMENT METHOD; FORGING; HARDNESS; JOINTS; LAYERS; LOADING; MACHINE TOOLS; PLATES; RESIDUAL STRESSES; SERVICE LIFE; STEELS; TEMPERING; WEAR

Citation Formats

Behrens, B -A, Schaefer, F, and Bistron, M. Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis. United States: N. p., 2007. Web. doi:10.1063/1.2740941.
Behrens, B -A, Schaefer, F, & Bistron, M. Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis. United States. https://doi.org/10.1063/1.2740941
Behrens, B -A, Schaefer, F, and Bistron, M. 2007. "Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis". United States. https://doi.org/10.1063/1.2740941.
@article{osti_21061787,
title = {Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis},
author = {Behrens, B -A and Schaefer, F and Bistron, M},
abstractNote = {The tools in hot forging processes are exposed to high thermal and mechanical loadings. Tempering of the tool edge layer occurs as a result of thermal loadings. This leads to a gradual hardness loss of the tool material and increase of wear over forging cycles. Hence, the tool life in hot forging is mainly limited by wear. An extension of the die service life can be achieved by the use of ceramic inserts. The integration of ceramics into the die base plate made of hot-work steel is realised by active brazing, whereby it possible to apply ceramic in region with high wear. It has to be ensured in the design process of ceramic inserts for forging dies that no critical tensile stresses occur in the ceramics. A reliable design of the ceramic inserts is possible only through consideration of brazing and forming process. The development of a Finite-Element-model for the design of forging dies with ceramic inserts is the intention of the work presented in this paper. At first the forging process with a conventional die is analyzed concerning abrasive die wear to identify regions with high wear risk applying a modified Archard model. Based on the results of wear calculation, a forging die with ceramic inserts is investigated in terms of joint stresses at the end of the active brazing process. Subsequently, the forging process considering the residual stresses caused by joining is simulated in order to obtain the die stress in use.},
doi = {10.1063/1.2740941},
url = {https://www.osti.gov/biblio/21061787}, journal = {AIP Conference Proceedings},
issn = {0094-243X},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}