Potential of near-surface temperature regulation in hybrid additive manufactured forging dies

authored by: Julius Peddinghaus, Martin Siegmund, Janina Siring, Hendrik Wester, Jochen Giedenbacher, Adis Huskic, Bernd-Arno Behrens, Kai Brunotte
Abstract: Recent advances in the field of additive manufacturing (AM) have enabled the utilisation of Laser Powder Bed Fusion (L-PBF) for tool steels under high load conditions. Design elements, such as internal cooling channels, which are not achievable through subtractive manufacturing can therefore be used to functionalise and optimise hot forging tools. Thermal control is crucial for hot forging dies as the performance and endurance of the tools is highly dependent on the input and dissipation of heat in the surface zone during forging. A modified forging tool with conformal internal cooling channels generated through a hybrid L-PBF manufacturing process was developed in prior work. The objective in the presented research is the experimental evaluation of the effect of conformal temperature control in the novel tool concept on the temperature dependent tool deterioration mechanisms in forging conditions. The actively controlled water temperature was varied between room temperature for maximum cooling and 180 °C, representing an exemplary base temperature in steady state serial forging. After 1,000 cycles, the tool wear conditions are analysed optically and through destructive microstructure analysis to characterise the effect of the temperature management on the deterioration mechanisms. The results show a significant impact of subsurface temperature control on the wear mechanisms of forging dies. Abrasive wear can be limited to a minimum through internal cooling with major reduction in thermal loads. Increased base temperatures reduce run-in time but increase abrasion.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Upper Austria University of Applied Sciences
Type: Conference contribution
Pages: 891-900
No. of pages: 10
Publication date: 2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: General Materials Science
Electronic version(s): https://doi.org/10.21741/9781644903131-97 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{37601b546dea44169ed8455efe8a3e54,
title = "Potential of near-surface temperature regulation in hybrid additive manufactured forging dies",
abstract = "Recent advances in the field of additive manufacturing (AM) have enabled the utilisation of Laser Powder Bed Fusion (L-PBF) for tool steels under high load conditions. Design elements, such as internal cooling channels, which are not achievable through subtractive manufacturing can therefore be used to functionalise and optimise hot forging tools. Thermal control is crucial for hot forging dies as the performance and endurance of the tools is highly dependent on the input and dissipation of heat in the surface zone during forging. A modified forging tool with conformal internal cooling channels generated through a hybrid L-PBF manufacturing process was developed in prior work. The objective in the presented research is the experimental evaluation of the effect of conformal temperature control in the novel tool concept on the temperature dependent tool deterioration mechanisms in forging conditions. The actively controlled water temperature was varied between room temperature for maximum cooling and 180 °C, representing an exemplary base temperature in steady state serial forging. After 1,000 cycles, the tool wear conditions are analysed optically and through destructive microstructure analysis to characterise the effect of the temperature management on the deterioration mechanisms. The results show a significant impact of subsurface temperature control on the wear mechanisms of forging dies. Abrasive wear can be limited to a minimum through internal cooling with major reduction in thermal loads. Increased base temperatures reduce run-in time but increase abrasion.",
keywords = "Additive Manufacturing, Forging, Wear Protection",
author = "Julius Peddinghaus and Martin Siegmund and Janina Siring and Hendrik Wester and Jochen Giedenbacher and Adis Huskic and Bernd-Arno Behrens and Kai Brunotte",
note = "Publisher Copyright: {\textcopyright} 2024, Association of American Publishers. All rights reserved.",
year = "2024",
doi = "10.21741/9781644903131-97",
language = "English",
isbn = "9781644903131",
series = "Materials Research Proceedings",
pages = "891--900",
editor = "Araujo, {Anna Carla} and Arthur Cantarel and France Chabert and Adrian Korycki and Philippe Olivier and Fabrice Schmidt",
booktitle = "Materials Research Proceedings",
}