Application of numerical simulation for wear analysis of warm forging die

Abstract

Warm forging process has better forming precision than hot forging process and has better formability than cold forging. But warm forging die sustains higher temperature and working pressure, the die wear is faster than those of hot forging and cold forging. The purpose of this research is to combine the experimental techniques, wear model and numerical simulation method to predict the wear of warm forging die. The non-isothermal ring compression test was adopted to estimate the friction coefficient in different temperatures and the on-line temperature recording system was setup to correct the heat transfer coefficient of the interface. The wear coefficients in different temperatures were acquired from high temperature wear experiment. Finally, the Archard wear theory and DEFORM, a FEM code, were used to analyze the warm forging of automotive transmission outer-race and predict the die wear condition.