Further Development of Wear Calculation and Wear Reduction in Cold Forging Processes

authored by: Bernd-Arno Behrens, Kai Brunotte, Sven Hübner, Hendrik Wester, Felix Müller, Philipp Müller, Jonas Wälder, Tim Matthias
Abstract: Tools are of strategic importance for industrial manufacturing processes. Their behaviour has a great influence on the productivity of the process and the quality of the product. A material saving and efficient technique for processing metallic workpieces is cold forging. One major challenge of this production method is the handling of high contact normal stresses in the tool contact, which can lead to severe tool wear. To investigate promising approaches for understanding wear modelling and wear reduction a demonstrator process based on the first stage of a total five-staged cold forging process for the manufacturing of a bolt anchor is considered in the scope of this research. This work aims at the further development of a numerical wear calculation based on an adapted Archard model in order to be able to realistically predict the tool wear in cold forging processes. Therefore, the material characterization of the used workpiece material as well as an investigation of the worn tool dies takes place to validate a numerical wear calculation model. Furthermore, this research addresses a reduction in wear by identifying critical areas and changing the inlet geometry of the investigated demonstrator tool die. This way, conclusions can be drawn about the wear sensitivity during numerical process design, and particularly critical areas can be geometrically modified in terms of the design.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): fischerwerke GmbH & Co. KG
Type: Article
Journal: Journal of Manufacturing and Materials Processing
Volume: 5
Publication date: 13.04.2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanics of Materials, Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.3390/jmmp5020036 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{5235af1f872648e5980f6ff82933b3b5,
title = "Further Development of Wear Calculation and Wear Reduction in Cold Forging Processes",
abstract = "Tools are of strategic importance for industrial manufacturing processes. Their behaviour has a great influence on the productivity of the process and the quality of the product. A material saving and efficient technique for processing metallic workpieces is cold forging. One major challenge of this production method is the handling of high contact normal stresses in the tool contact, which can lead to severe tool wear. To investigate promising approaches for understanding wear modelling and wear reduction a demonstrator process based on the first stage of a total five-staged cold forging process for the manufacturing of a bolt anchor is considered in the scope of this research. This work aims at the further development of a numerical wear calculation based on an adapted Archard model in order to be able to realistically predict the tool wear in cold forging processes. Therefore, the material characterization of the used workpiece material as well as an investigation of the worn tool dies takes place to validate a numerical wear calculation model. Furthermore, this research addresses a reduction in wear by identifying critical areas and changing the inlet geometry of the investigated demonstrator tool die. This way, conclusions can be drawn about the wear sensitivity during numerical process design, and particularly critical areas can be geometrically modified in terms of the design.",
keywords = "Cold forging, Finite element method, Parametric investigation, Tool geometry, Wear",
author = "Bernd-Arno Behrens and Kai Brunotte and Sven H{\"u}bner and Hendrik Wester and Felix M{\"u}ller and Philipp M{\"u}ller and Jonas W{\"a}lder and Tim Matthias",
note = "Funding Information: Funding: The authors gratefully acknowledge the financial support of the German Research Foundation (DFG) within the transregional collaborative research center TCRC73 “Manufacturing of complex functional components with variants by using a new sheet metal forming process—Sheet Bulk Metal Forming” project T06-417860413.",
year = "2021",
month = apr,
day = "13",
doi = "10.3390/jmmp5020036",
language = "English",
volume = "5",
journal = "Journal of Manufacturing and Materials Processing",
issn = "2504-4494",
publisher = "MDPI Multidisciplinary Digital Publishing Institute",
number = "2",
}