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Marek Hawryluk - One of the best experts on this subject based on the ideXlab platform.
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Identification of the relations between the process conditions and the Forging Tool wear by combined experimental and numerical investigations
CIRP Journal of Manufacturing Science and Technology, 2020Co-Authors: Marek Hawryluk, S. Polak, Zbigniew Gronostajski, Marcin Kaszuba, Jacek ZiembaAbstract:Abstract The research of the wear of a punch used to forge a cover-type Forging proved a dominance of different destructive mechanisms in the particular areas of the Tools. The preliminary analysis, based on many years of verified experience of the authors, showed that, in most of the working part of the Forging Tool, especially in flat front area, there are various degradation mechanisms, such as: thermo-mechanical fatigue, plastic deformation and material spalling, which are critical and whose share is difficult to estimate. While in the different working surface of this Tool, like in radii, it can be assumed that the dominant mechanism of destruction is only abrasive wear. In both of these areas, the loss of the material was dependent on the contact conditions (the main are: stresses, temperature, friction and lubrication conditions) between the forged material and the Tool, as well as the geometry of both. The obtained analysis outcomes have been confirmed for Tools after Forging: 6000, 9000 and 12,000 Forgings; for each number of cycles, three Tools were used to ensure repeatability of the operating results. The progressing geometry change of the Tools as effect of material loss (determined by repeatedly by verified the 3D reverse scanning method) was presented in the form of a diagram, depending on the number of the forged elements, which resembles the classic (Lorentz) wear curve for flat front area and an almost linear wear curve for radii area with only abrasive wear. The research perfomed by means of numerical modeling confirmed that, in the last period of the Tools’ operation, a drop of wear intensity is visible.
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Selected effective methods of increasing the durability of Forging Tools in hot Forging processes
Procedia Manufacturing, 2019Co-Authors: Zbigniew Gronostajski, Marek Hawryluk, Paweł Widomski, S. Polak, Jacek Ziemba, Marcin Kaszuba, B. Nowak, M. Rychlik, M. ZwierzchowskiAbstract:Abstract The paper presents the possibilities of applying selected methods and techniques which increase the Forging Tool durability. Currently, the most popular of them include: the choice of the Tool material for a given process or operation, its heat and thermo-chemical treatment, the surface engineering techniques (nitriding, hybrid layers, etc.). It is also important to select the appropriate technological conditions (e.g. related to the determination of the optimal temperatures, application of the cooling-lubricant method as well the method of its administration), or construction and technological solutions, as well as control and measurement systems, which can be the systems for supervising the work of the Tools. The application of the proposed methods realized in cooperation with the Forging industry exhibits the highest effectiveness in improving the durability of Forging Tools as well as resolving many problems related to the quality and properties of the Forgings.
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Analysis of wear mechanisms of hot Forging Tools protected with hybrid layers performed by nitriding and PVD coatings deposition
Wear, 2019Co-Authors: Zbigniew Gronostajski, Paweł Widomski, Jacek Ziemba, Marcin Kaszuba, Jerzy Smolik, Marek HawrylukAbstract:Abstract This article presents the results of research on hybrid layers used to increase the durability of hot Forging Tools. The aim of the work is to uniformly compare mechanisms of wear of different hybrid layers deposited simultaneously on one Forging Tool for this purpose. The test Tool was made of hot working Tool steel X37CrMoV5-1, and the raw parts in the test Forging process were made of 16MnCr5 steel. The Tool was divided into four zones: gas nitrided substrate (GN), GN and Cr / CrN coating, GN and Cr / CrN / AlCrTiN coating, GN and CrN / AlCrN / AlCrTiSiN coating. Because the Tool is axially symmetrical, each zone was subjected to destructive mechanisms during the Forging process in the same way. After exploitation, the Tool was analyzed for the destructive mechanisms occurring in the surface layer. It is believed that the main destructive mechanism is abrasive wear, which is intensified by thermal and mechanical fatigue, adhesive wear, the tempering of the surface layer and oxidation. In the analyzed case, the dominant influence of thermo-mechanical fatigue was observed in the form of a grid of cracks present on the surface of the Forging die. The surface of Tools was analyzed in light and SEM microscopy, surface roughness was tested at various stages of exploitation, the geometry of Tools used was measured using a laser scanner and GOM software, and the microhardness and microstructure of hybrid layers after exploitation were analyzed. In addition, to determine how the properties of hybrid layers change during work, the scratch test was performed, in which the adhesion of the coating to the substrate was determined on the surface of specimens taken from a Tool after exploitation. The results showed differences in the wear mechanisms observed on all analyzed layers and changes in properties in the surface layer that already occurred at an early stage of exploitation.
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Influence of application of GN+Cr/CrN hybrid layer on durability improvement of die inserts used in hot Forging process of wheel Forging
Procedia Manufacturing, 2018Co-Authors: Zbigniew Gronostajski, Marek Hawryluk, Paweł Widomski, S. Polak, Jacek Ziemba, M. ZwierzchowskiAbstract:Abstract This work presents the results of tests of Forging Tools in a hot Forging process of wheel Forgings. The upper die inserts with GN+Cr/CrN hybrid layer, applied to improve their durability, were tested in comparison the a gas-nitrided Tool. The hybrid layer was produced on a plasma-nitrided substrate, onto which a PVD Cr/CrN coating was deposited. All Tools were checked and analyzed for changes in the surface layer under a complex research including: analysis of process conditions, macroscopic and geometrical analysis (by scanning), as well SEM research microscopy. The tests confirmed the effect of an improved Forging Tool durability in case of application of the GN+Cr/CrN hybrid layer in relation to the hitherto used -gas nitriding.
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Lubrication in hot die Forging processes
Proceedings of the Institution of Mechanical Engineers Part J: Journal of Engineering Tribology, 2018Co-Authors: Marek Hawryluk, Jacek ZiembaAbstract:This article presents selected aspects of lubricant application, as well as lubrication methods and devices in the context of Forging Tool durability and accessories used in die Forging processes at elevated temperatures. The properties and applications of the currently used lubricating and cooling agents in selected industrial Forging processes were analyzed. The authors’ original studies on the influence of lubricant application, dose size, time and feed direction as well as other factors affecting tribological conditions are also presented. A review of lubricating and cooling systems and devices is provided, as well as a lubricating device built on the basis of the authors’ knowledge and experience is presented. The developed system, implemented into an industrial process, makes it possible to select and maintain its optimal tribological conditions through the control of the size and frequency of the administered lubricant dose. It may be an alternative to the manual lubricant application method, where...
Jacek Ziemba - One of the best experts on this subject based on the ideXlab platform.
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Identification of the relations between the process conditions and the Forging Tool wear by combined experimental and numerical investigations
CIRP Journal of Manufacturing Science and Technology, 2020Co-Authors: Marek Hawryluk, S. Polak, Zbigniew Gronostajski, Marcin Kaszuba, Jacek ZiembaAbstract:Abstract The research of the wear of a punch used to forge a cover-type Forging proved a dominance of different destructive mechanisms in the particular areas of the Tools. The preliminary analysis, based on many years of verified experience of the authors, showed that, in most of the working part of the Forging Tool, especially in flat front area, there are various degradation mechanisms, such as: thermo-mechanical fatigue, plastic deformation and material spalling, which are critical and whose share is difficult to estimate. While in the different working surface of this Tool, like in radii, it can be assumed that the dominant mechanism of destruction is only abrasive wear. In both of these areas, the loss of the material was dependent on the contact conditions (the main are: stresses, temperature, friction and lubrication conditions) between the forged material and the Tool, as well as the geometry of both. The obtained analysis outcomes have been confirmed for Tools after Forging: 6000, 9000 and 12,000 Forgings; for each number of cycles, three Tools were used to ensure repeatability of the operating results. The progressing geometry change of the Tools as effect of material loss (determined by repeatedly by verified the 3D reverse scanning method) was presented in the form of a diagram, depending on the number of the forged elements, which resembles the classic (Lorentz) wear curve for flat front area and an almost linear wear curve for radii area with only abrasive wear. The research perfomed by means of numerical modeling confirmed that, in the last period of the Tools’ operation, a drop of wear intensity is visible.
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Selected effective methods of increasing the durability of Forging Tools in hot Forging processes
Procedia Manufacturing, 2019Co-Authors: Zbigniew Gronostajski, Marek Hawryluk, Paweł Widomski, S. Polak, Jacek Ziemba, Marcin Kaszuba, B. Nowak, M. Rychlik, M. ZwierzchowskiAbstract:Abstract The paper presents the possibilities of applying selected methods and techniques which increase the Forging Tool durability. Currently, the most popular of them include: the choice of the Tool material for a given process or operation, its heat and thermo-chemical treatment, the surface engineering techniques (nitriding, hybrid layers, etc.). It is also important to select the appropriate technological conditions (e.g. related to the determination of the optimal temperatures, application of the cooling-lubricant method as well the method of its administration), or construction and technological solutions, as well as control and measurement systems, which can be the systems for supervising the work of the Tools. The application of the proposed methods realized in cooperation with the Forging industry exhibits the highest effectiveness in improving the durability of Forging Tools as well as resolving many problems related to the quality and properties of the Forgings.
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Analysis of wear mechanisms of hot Forging Tools protected with hybrid layers performed by nitriding and PVD coatings deposition
Wear, 2019Co-Authors: Zbigniew Gronostajski, Paweł Widomski, Jacek Ziemba, Marcin Kaszuba, Jerzy Smolik, Marek HawrylukAbstract:Abstract This article presents the results of research on hybrid layers used to increase the durability of hot Forging Tools. The aim of the work is to uniformly compare mechanisms of wear of different hybrid layers deposited simultaneously on one Forging Tool for this purpose. The test Tool was made of hot working Tool steel X37CrMoV5-1, and the raw parts in the test Forging process were made of 16MnCr5 steel. The Tool was divided into four zones: gas nitrided substrate (GN), GN and Cr / CrN coating, GN and Cr / CrN / AlCrTiN coating, GN and CrN / AlCrN / AlCrTiSiN coating. Because the Tool is axially symmetrical, each zone was subjected to destructive mechanisms during the Forging process in the same way. After exploitation, the Tool was analyzed for the destructive mechanisms occurring in the surface layer. It is believed that the main destructive mechanism is abrasive wear, which is intensified by thermal and mechanical fatigue, adhesive wear, the tempering of the surface layer and oxidation. In the analyzed case, the dominant influence of thermo-mechanical fatigue was observed in the form of a grid of cracks present on the surface of the Forging die. The surface of Tools was analyzed in light and SEM microscopy, surface roughness was tested at various stages of exploitation, the geometry of Tools used was measured using a laser scanner and GOM software, and the microhardness and microstructure of hybrid layers after exploitation were analyzed. In addition, to determine how the properties of hybrid layers change during work, the scratch test was performed, in which the adhesion of the coating to the substrate was determined on the surface of specimens taken from a Tool after exploitation. The results showed differences in the wear mechanisms observed on all analyzed layers and changes in properties in the surface layer that already occurred at an early stage of exploitation.
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Influence of application of GN+Cr/CrN hybrid layer on durability improvement of die inserts used in hot Forging process of wheel Forging
Procedia Manufacturing, 2018Co-Authors: Zbigniew Gronostajski, Marek Hawryluk, Paweł Widomski, S. Polak, Jacek Ziemba, M. ZwierzchowskiAbstract:Abstract This work presents the results of tests of Forging Tools in a hot Forging process of wheel Forgings. The upper die inserts with GN+Cr/CrN hybrid layer, applied to improve their durability, were tested in comparison the a gas-nitrided Tool. The hybrid layer was produced on a plasma-nitrided substrate, onto which a PVD Cr/CrN coating was deposited. All Tools were checked and analyzed for changes in the surface layer under a complex research including: analysis of process conditions, macroscopic and geometrical analysis (by scanning), as well SEM research microscopy. The tests confirmed the effect of an improved Forging Tool durability in case of application of the GN+Cr/CrN hybrid layer in relation to the hitherto used -gas nitriding.
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Lubrication in hot die Forging processes
Proceedings of the Institution of Mechanical Engineers Part J: Journal of Engineering Tribology, 2018Co-Authors: Marek Hawryluk, Jacek ZiembaAbstract:This article presents selected aspects of lubricant application, as well as lubrication methods and devices in the context of Forging Tool durability and accessories used in die Forging processes at elevated temperatures. The properties and applications of the currently used lubricating and cooling agents in selected industrial Forging processes were analyzed. The authors’ original studies on the influence of lubricant application, dose size, time and feed direction as well as other factors affecting tribological conditions are also presented. A review of lubricating and cooling systems and devices is provided, as well as a lubricating device built on the basis of the authors’ knowledge and experience is presented. The developed system, implemented into an industrial process, makes it possible to select and maintain its optimal tribological conditions through the control of the size and frequency of the administered lubricant dose. It may be an alternative to the manual lubricant application method, where...
S S Kang - One of the best experts on this subject based on the ideXlab platform.
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New Forging Tool manufacturing method for spur gear part
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2007Co-Authors: Jong Hun Kang, K O Lee, S S KangAbstract:AbstractThis study introduces an advanced Tool manufacturing method regarding manufacturing procedures. With conventional methods, wire-cutting and lapping operations of the corner and render regions are performed after shrink fitting to ensure the accuracy of the gear profile. However, lapping is very difficult when the corner and render are located deep inside the die. The new Tool manufacturing method suggests that wire cutting and lapping are performed after the first shrink fitting to facilitate the lapping operation and increase the accuracy of the corner radius. After lapping is completed, the second die ring is shrink fitted. The amount of elastic deformation by the second shrink fitting and cold Forging can be calculated through finite element analysis. Wire-cutting specifications can be offset as predicted in terms of the amount of elastic deformation. Gear dimension comparison of the analysis and forged parts ensures the validity of the new Tool manufacturing method.
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spur gear Forging Tool manufacturing method considering elastic deformation due to shrink fitting
Journal of Materials Processing Technology, 2007Co-Authors: Jong Hun Kang, Kyunghun Lee, S S KangAbstract:Abstract This research introduces an advanced manufacturing method for gear part Tools. In the conventional method, wire cutting and lapping of the corner region were performed after shrink fitting to ensure the accuracy of the gear profile. But lapping is difficult when the corner region is located inside of the die. The new Tool manufacturing method suggests that wire cutting and lapping are performed after the 1st shrink fitting to facilitate lapping operation and to increase the accuracy of the corner radius. Finite element analysis and Forging test are performed. Comparison between analysis and measurement of forged part ensures the validity of suggested Tool manufacturing methods.
Trevor A. Dean - One of the best experts on this subject based on the ideXlab platform.
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A parametric CAD program for die sets for precision Forging spur gears
International Journal of Machine Tools and Manufacture, 1991Co-Authors: V.m. Drecun, Trevor A. DeanAbstract:Abstract This paper describes a parametric modelling technique implemented in software for Tool design for precision Forging straight and helical spur gears. In order to increase required design times and to provide an optimal choice of die dimensions variational solid modelling is used for automated machining of Forging Tool parts.
Zbigniew Gronostajski - One of the best experts on this subject based on the ideXlab platform.
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Identification of the relations between the process conditions and the Forging Tool wear by combined experimental and numerical investigations
CIRP Journal of Manufacturing Science and Technology, 2020Co-Authors: Marek Hawryluk, S. Polak, Zbigniew Gronostajski, Marcin Kaszuba, Jacek ZiembaAbstract:Abstract The research of the wear of a punch used to forge a cover-type Forging proved a dominance of different destructive mechanisms in the particular areas of the Tools. The preliminary analysis, based on many years of verified experience of the authors, showed that, in most of the working part of the Forging Tool, especially in flat front area, there are various degradation mechanisms, such as: thermo-mechanical fatigue, plastic deformation and material spalling, which are critical and whose share is difficult to estimate. While in the different working surface of this Tool, like in radii, it can be assumed that the dominant mechanism of destruction is only abrasive wear. In both of these areas, the loss of the material was dependent on the contact conditions (the main are: stresses, temperature, friction and lubrication conditions) between the forged material and the Tool, as well as the geometry of both. The obtained analysis outcomes have been confirmed for Tools after Forging: 6000, 9000 and 12,000 Forgings; for each number of cycles, three Tools were used to ensure repeatability of the operating results. The progressing geometry change of the Tools as effect of material loss (determined by repeatedly by verified the 3D reverse scanning method) was presented in the form of a diagram, depending on the number of the forged elements, which resembles the classic (Lorentz) wear curve for flat front area and an almost linear wear curve for radii area with only abrasive wear. The research perfomed by means of numerical modeling confirmed that, in the last period of the Tools’ operation, a drop of wear intensity is visible.
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Selected effective methods of increasing the durability of Forging Tools in hot Forging processes
Procedia Manufacturing, 2019Co-Authors: Zbigniew Gronostajski, Marek Hawryluk, Paweł Widomski, S. Polak, Jacek Ziemba, Marcin Kaszuba, B. Nowak, M. Rychlik, M. ZwierzchowskiAbstract:Abstract The paper presents the possibilities of applying selected methods and techniques which increase the Forging Tool durability. Currently, the most popular of them include: the choice of the Tool material for a given process or operation, its heat and thermo-chemical treatment, the surface engineering techniques (nitriding, hybrid layers, etc.). It is also important to select the appropriate technological conditions (e.g. related to the determination of the optimal temperatures, application of the cooling-lubricant method as well the method of its administration), or construction and technological solutions, as well as control and measurement systems, which can be the systems for supervising the work of the Tools. The application of the proposed methods realized in cooperation with the Forging industry exhibits the highest effectiveness in improving the durability of Forging Tools as well as resolving many problems related to the quality and properties of the Forgings.
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Analysis of wear mechanisms of hot Forging Tools protected with hybrid layers performed by nitriding and PVD coatings deposition
Wear, 2019Co-Authors: Zbigniew Gronostajski, Paweł Widomski, Jacek Ziemba, Marcin Kaszuba, Jerzy Smolik, Marek HawrylukAbstract:Abstract This article presents the results of research on hybrid layers used to increase the durability of hot Forging Tools. The aim of the work is to uniformly compare mechanisms of wear of different hybrid layers deposited simultaneously on one Forging Tool for this purpose. The test Tool was made of hot working Tool steel X37CrMoV5-1, and the raw parts in the test Forging process were made of 16MnCr5 steel. The Tool was divided into four zones: gas nitrided substrate (GN), GN and Cr / CrN coating, GN and Cr / CrN / AlCrTiN coating, GN and CrN / AlCrN / AlCrTiSiN coating. Because the Tool is axially symmetrical, each zone was subjected to destructive mechanisms during the Forging process in the same way. After exploitation, the Tool was analyzed for the destructive mechanisms occurring in the surface layer. It is believed that the main destructive mechanism is abrasive wear, which is intensified by thermal and mechanical fatigue, adhesive wear, the tempering of the surface layer and oxidation. In the analyzed case, the dominant influence of thermo-mechanical fatigue was observed in the form of a grid of cracks present on the surface of the Forging die. The surface of Tools was analyzed in light and SEM microscopy, surface roughness was tested at various stages of exploitation, the geometry of Tools used was measured using a laser scanner and GOM software, and the microhardness and microstructure of hybrid layers after exploitation were analyzed. In addition, to determine how the properties of hybrid layers change during work, the scratch test was performed, in which the adhesion of the coating to the substrate was determined on the surface of specimens taken from a Tool after exploitation. The results showed differences in the wear mechanisms observed on all analyzed layers and changes in properties in the surface layer that already occurred at an early stage of exploitation.
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Influence of application of GN+Cr/CrN hybrid layer on durability improvement of die inserts used in hot Forging process of wheel Forging
Procedia Manufacturing, 2018Co-Authors: Zbigniew Gronostajski, Marek Hawryluk, Paweł Widomski, S. Polak, Jacek Ziemba, M. ZwierzchowskiAbstract:Abstract This work presents the results of tests of Forging Tools in a hot Forging process of wheel Forgings. The upper die inserts with GN+Cr/CrN hybrid layer, applied to improve their durability, were tested in comparison the a gas-nitrided Tool. The hybrid layer was produced on a plasma-nitrided substrate, onto which a PVD Cr/CrN coating was deposited. All Tools were checked and analyzed for changes in the surface layer under a complex research including: analysis of process conditions, macroscopic and geometrical analysis (by scanning), as well SEM research microscopy. The tests confirmed the effect of an improved Forging Tool durability in case of application of the GN+Cr/CrN hybrid layer in relation to the hitherto used -gas nitriding.
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Influence of the application of a PN+Cr/CrN hybrid layer on the improvement of the lifetime of hot Forging Tools
Journal of Materials Processing Technology, 2018Co-Authors: Marek Hawryluk, Paweł Widomski, Jacek Ziemba, Zbigniew Gronostajski, Marcin Kaszuba, Jerzy SmolikAbstract:Abstract This article presents the results of field tests performed on Forging Tools in a selected lid hot Forging process. The aim of the studies was to increase the durability of hot Forging Tools. Different coating types dedicated to hot Forging Tools were proposed and first tested in laboratory conditions. Based on the laboratory test results, the PN + Cr/CrN hybrid layer was selected to improve Tool durability. Tools (upper punches used in second Forging operation) with a PN + Cr/CrN layer applied on them were tested in comparison with gas-nitrided Tools. The hybrid layer was produced on a plasma-nitrided substrate, onto which a PVD Cr/CrN coating was deposited. All the analyzed Tools were tested in industrial conditions through the manufacturing of specific quantities of Forgings. Next, the wear of each Tool was analyzed by surface scanning and then compared to the CAD model. All the Tools were checked for changes in the surface layer under an optical and a scanning electron microscope, as well as by way of a microhardness measurement. The results obtained in industrial conditions confirmed the effect of improvement of the Forging Tool lifetime owed to the application of the PN + Cr/CrN hybrid layer.