Abstract
The aim of the research was to create a methodology that will enable effective and reliable prediction of the tool wear. The idea of the hybrid model, which accounts for various mechanisms of tool material deterioration, is proposed in the paper. The mechanisms, which were considered, include abrasive wear, adhesive wear, thermal fatigue, mechanical fatigue, oxidation and plastic deformation. Individual models of various complexity were used for separate phenomena and strategy of combination of these models in one hybrid system was developed to account for the synergy of various mechanisms. The complex hybrid model was built on the basis of these individual models for various wear mechanisms. The individual models expanded from phenomenological ones for abrasive wear to multi-scale methods for modelling micro cracks initiation and propagation utilizing virtual representations of granular microstructures. The latter have been intensively developed recently and they form potentially a powerful tool that allows modelling of thermal and mechanical fatigue, accounting explicitly for the tool material microstructure.
Highlights
In industrial hot forging processes, prediction of die wear is critical for optimization of costs and materials usage
Majority of wear models used today in engineering applications is focused on one mechanism, while effects of other are ignored
Even in a single process, in different parts of die different wear mechanisms may be of primary effect
Summary
In industrial hot forging processes, prediction of die wear is critical for optimization of costs and materials usage. Majority of wear models used today in engineering applications is focused on one mechanism, while effects of other are ignored. This approach makes the wear prediction less useful, especially if wear in large product series (industrial application) is calculated. Even in a single process, in different parts of die different wear mechanisms may be of primary effect. Dies for hot forging usually have surfaces enhanced some way (thermal processing, nitriding, etc.), so after enriched layer wears off, other wear mechanisms occur and different die material and surface parameters have to be used. Creating a methodology that will enable effective and reliable prediction of the tool wear was the main objective
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