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.
Highlights
IntroductionCold forming is an economical process for manufacturing workpieces with good surface qualities, manufacturing accuracies and material properties in large quantities [1,2]
Introduction and MotivationCold forming is an economical process for manufacturing workpieces with good surface qualities, manufacturing accuracies and material properties in large quantities [1,2].Compared to other manufacturing processes, cold forming requires less material, fewer manufacturing steps and less energy for the production of a finished part [2]
By calculating the tool wear based on the frictional shear stress according to Shaw’s
Summary
Cold forming is an economical process for manufacturing workpieces with good surface qualities, manufacturing accuracies and material properties in large quantities [1,2]. Compared to other manufacturing processes, cold forming requires less material, fewer manufacturing steps and less energy for the production of a finished part [2]. The tool materials must have high strengths in order to not suffer plastic deformation under these operating conditions [5]. The plastic deformation of the tools would reduce the dimensional accuracy of the produced workpieces [6] and could lead to total tool failure [7]. The tool life required for an economic production can only be achieved if tool wear is reduced . The components to be produced should not have any critical corners, in order to avoid premature wear of the forming tools [7]
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