Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging
The article performs an analysis of the durability of punches applied in the process of producing a valve forging from chromium-nickel steel. A forging of this type is made in two operations: coextrusion of a long shank, followed by finishing forging in closed dies of the valve head. The product obt...
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-11-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/14/22/7063 |
| _version_ | 1797509529061031936 |
|---|---|
| author | Marek Hawryluk Jacek Ziemba Marta Janik Piotr Górski Łukasz Dudkiewicz Kornelia Głód Jakub Krawczyk |
| author_facet | Marek Hawryluk Jacek Ziemba Marta Janik Piotr Górski Łukasz Dudkiewicz Kornelia Głód Jakub Krawczyk |
| author_sort | Marek Hawryluk |
| collection | DOAJ |
| description | The article performs an analysis of the durability of punches applied in the process of producing a valve forging from chromium-nickel steel. A forging of this type is made in two operations: coextrusion of a long shank, followed by finishing forging in closed dies of the valve head. The product obtained in this way (after other additional finishing procedures) constitutes the key element of the combustion engine (resistant to high pressures and temperatures) in motor trucks. Unfortunately, a significant problem in this production process is a relatively low durability of the forging tools, especially the punch used in the second forging operation. The key element at this stage, deciding about the punch’s further operation, is the area of the so-called “calotte”. The short-term life of the tools results from very hard performance conditions present during the forging process (periodical high mechanical and thermal loads, long path of friction). The latter cause intensive abrasive wear as well as high adhesion of the forging material to the tool surface. Based on the performed studies, including the following: technology analysis, numerical modelling, macro analyses combined with 3D scanning of tool sections as well as microstructural tests and hardness measurements, it was established that it is crucial to properly select the process parameters (charge and tool temperature, tribological conditions), as even slight changes introduced into them significantly affect the operation time of the forging tools. Mastering and proper implementation of the analyzed forging technology requires numerous further studies and tests, which will enable its perfection and thus increase the durability of the tools as well as the quality of the produced items. |
| first_indexed | 2024-03-10T05:19:03Z |
| format | Article |
| id | doaj.art-aa2af14c123c4806b15e49527e70d411 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T05:19:03Z |
| publishDate | 2021-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-aa2af14c123c4806b15e49527e70d4112023-11-23T00:13:06ZengMDPI AGMaterials1996-19442021-11-011422706310.3390/ma14227063Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve ForgingMarek Hawryluk0Jacek Ziemba1Marta Janik2Piotr Górski3Łukasz Dudkiewicz4Kornelia Głód5Jakub Krawczyk6Department of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, 50-370 Wroclaw, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, 50-370 Wroclaw, PolandValves Department, Mahle Poland, Mahle 6, 63-700 Krotoszyn, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, 50-370 Wroclaw, PolandSchraner Polska, 99-100 Łeczyca, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, 50-370 Wroclaw, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, 50-370 Wroclaw, PolandThe article performs an analysis of the durability of punches applied in the process of producing a valve forging from chromium-nickel steel. A forging of this type is made in two operations: coextrusion of a long shank, followed by finishing forging in closed dies of the valve head. The product obtained in this way (after other additional finishing procedures) constitutes the key element of the combustion engine (resistant to high pressures and temperatures) in motor trucks. Unfortunately, a significant problem in this production process is a relatively low durability of the forging tools, especially the punch used in the second forging operation. The key element at this stage, deciding about the punch’s further operation, is the area of the so-called “calotte”. The short-term life of the tools results from very hard performance conditions present during the forging process (periodical high mechanical and thermal loads, long path of friction). The latter cause intensive abrasive wear as well as high adhesion of the forging material to the tool surface. Based on the performed studies, including the following: technology analysis, numerical modelling, macro analyses combined with 3D scanning of tool sections as well as microstructural tests and hardness measurements, it was established that it is crucial to properly select the process parameters (charge and tool temperature, tribological conditions), as even slight changes introduced into them significantly affect the operation time of the forging tools. Mastering and proper implementation of the analyzed forging technology requires numerous further studies and tests, which will enable its perfection and thus increase the durability of the tools as well as the quality of the produced items.https://www.mdpi.com/1996-1944/14/22/7063valve forgingdurability of forging punchwear of calotte areanumerical modelling |
| spellingShingle | Marek Hawryluk Jacek Ziemba Marta Janik Piotr Górski Łukasz Dudkiewicz Kornelia Głód Jakub Krawczyk Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging Materials valve forging durability of forging punch wear of calotte area numerical modelling |
| title | Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging |
| title_full | Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging |
| title_fullStr | Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging |
| title_full_unstemmed | Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging |
| title_short | Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging |
| title_sort | wear analysis of forging tools used in an industrial production process hot forging in closed dies of the head disk of an engine valve forging |
| topic | valve forging durability of forging punch wear of calotte area numerical modelling |
| url | https://www.mdpi.com/1996-1944/14/22/7063 |
| work_keys_str_mv | AT marekhawryluk wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging AT jacekziemba wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging AT martajanik wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging AT piotrgorski wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging AT łukaszdudkiewicz wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging AT korneliagłod wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging AT jakubkrawczyk wearanalysisofforgingtoolsusedinanindustrialproductionprocesshotforgingincloseddiesoftheheaddiskofanenginevalveforging |