Possibilities of Increasing the Durability of Punches Used in the Forging Process in Closed Dies of Valve Forgings by Using Alternative Materials from Tool Steels and Sintered Carbides

Possibilities of Increasing the Durability of Punches Used in the Forging Process in Closed Dies of Valve Forgings by Using Alternative Materials from Tool Steels and Sintered Carbides

This study refers to an analysis of the durability of forging tools applied in the second operation of producing a valve forging from the chromium-nickel steel, NC3015. Due to the extreme working conditions of the tools, caused by cyclic thermo-mechanical loads, the average durability of tools made...

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Bibliographic Details
Published in:Materials Vol. 17; no. 2; p. 370
Main Authors: Hawryluk, Marek, Janik, Marta, Gronostajski, Zbigniew, Barełkowki, Artur, Zwierzchowski, Maciej, Lachowicz, Marzena, Ziemba, Jacek, Marzec, Jan
Format: Journal Article
Language:English
Published: Switzerland MDPI AG 01-01-2024
Subjects:
Adhesive wear
Carbide tools
Costs
Cyclic loads
Die forgings
Durability
Finite volume method
Forging dies
Grain boundaries
Hardness
High speed tool steels
Inserts
Mechanical properties
Metal fatigue
Metalworking machinery
Microhardness
Nickel steel
Nickel steels
Numerical analysis
Optical microscopy
Parameters
Punches
Service life
Simulation methods
Sintering
Steel
Technology application
Tool-steel
Tribology
Valves
sintered carbides
valve forging
durability of forging tools
chromium–nickel steel
methods of increasing tool life
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Summary:This study refers to an analysis of the durability of forging tools applied in the second operation of producing a valve forging from the chromium-nickel steel, NC3015. Due to the extreme working conditions of the tools, caused by cyclic thermo-mechanical loads, the average durability of tools made from tool steel WLV (1.2365) equals about 1500 forgings. An in-depth, complex analysis was performed on the technology, using macroscopic tests combined with a measurement of the wear/allowance on the tool working surface through 3D scanning; microstructural tests by means of light microscopy; observations of the changes taking place on the working surface with a scanning electron microscope; microhardness measurements; and multi-variant numerical simulations. It was established that the key issue is the proper selection of the process technological parameters, such as the input material and tool temperature, friction, lubrication, tribological parameters, type of tool material, or punch design, because even small changes made to them significantly affect the service life of forging punches. Therefore, to increase the durability of the forging dies, alternative materials made of W360, as well as two high speed steels, S600 and S705, were applied. However, the implemented punch materials did not bring the assumed effect of increased durability, as the highest average durability of steel W60 equaled only 1500 forgings, whereas in the case of the tool steels, this was below 900 forgings. For this reason, at the further stage, punches with sintered carbide inserts were introduced, which made it possible to significantly improve the durability up to the level of as many as 20,000 forgings, which, at the same time, points to a promising direction of further studies on the use of materials and solutions of this type.
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ISSN:1996-1944
1996-1944
DOI:10.3390/ma17020370