Evaluation of Forging Die Defect by Considering Plastic Deformation and Abrasive Wear in a Hot Forged Axle Shaft

Abstract

In the hot forging process, an abrasive wear is a major problem in the manufacturing process which may possibly happen together with the plastic deformation. Both effects are difficult to distinguish in the real tooling. Finite Element Modeling (FEM) is a tool that use to simulate those phenomena in the hot forging process. However, some unknown factors are not directly obtained from the actual measurement. Thus, the sensitivity analysis is applied together with FEM to approximate those parameters. This research was to evaluate the die defects of the hot forged axle shaft process which were the plastic deformation and the abrasive wear. The reliable simulation modeling was developed by conducting the sensitivity analysis of the unknown parameters; heat transfer and friction coefficient, and compared the results with the experimental results. Then, the evaluation of the defects was performed by considering the effect of the plastic deformation and abrasive wear separately. The plastic deformation would be determined by comparing the effective stress with the yield strength of the die material at the same temperature. To predict abrasive wear in 3D space the die profile from the actual process was measured by CMM and then it was compared with that obtained by FEM. Archard’s model was used to predict the abrasive die wear in FEM. The variation of the K-values was significant to the wear prediction. According to this study, the average K-value obtained from different positions gives the best representative than considering only a single point K-value.