First Experimental and Numerical Study on the Use of Sheet Metal Die Covers for Wear Protection in Closed-Die Forging

Abstract:

To reduce the failure of dies by abrasive wear, mechanical fatigue and thermal fatigue in closed-die forging usually measures like nitriding, deposition of ceramic layers by Physical Vapour Deposition (PVD), Chemical Vapour Deposition (CVD) or deposition welding are used. However, after some time wear appears and the dies have to be replaced. A new concept implements sheet metal die covers, which are placed on the die engraving during forging and will absorb abrasive wear, thermal and mechanical load. The inexpensive cover will be replaced quickly by a new one after it is worn-out. This concept is regarded in a first numerical and experimental study by comparing a covered die (C) and an uncovered die (U) for the production of the same part. A one-time use of the die cover showed a reduction of the peak temperature by 140 K and of the temperature amplitude by 37 %. The temperature reduction and the increase of inner radii of the engraving to fit the 1mm thick die cover doubled the expected die life time. The experiment showed that the soft deep drawing steel DC04 is not suitable in the current case for a die cover and a higher strength sheet metal should be applied.

• Periodical: Key Engineering Materials (Volumes 651-653)
• Pages: 266-271
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.651-653.266
• Online since: July 2015
• Authors: Dirk Rosenstock*, Eric Thore Segebade, Gerhard Hirt
• Keywords: Closed-Die Forging, Coating, Die Cover, Die Life Time, Wear

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