Cold rotary forging is an advanced but very complicated metal forming technology with multifactor coupling interactive effects. The purpose of this paper is to utilise the finite element (FE) method to reveal the effect of the process parameters on the wear that occurs over the surfaces of the dies and workpiece in cold rotary forging. For this purpose, a three-dimensional (3D) elastic–plastic dynamic explicit FE model of cold rotary forging of 20CrMnTi alloy was developed using the FE software ABAQUS/Explicit, and its validity was verified experimentally. According to the valid 3D FE model, a parametric study was conducted, examining the effect of the major process parameters on the wear response and optimising the process parameters. The results of this research thoroughly reveal the complicated wear mechanisms over the dies and workpieces and provide an important guide for optimising the process parameters in cold rotary forging.
Get full access to this article
View all access options for this article.
References
1.
FelderEMontaguJL: ‘Friction and wear during the hot forging of steels’,Tribol. Int., 1980, 13, 61–68.
2.
LoSW: ‘Die–workpiece interfacial behaviors in axisymmetric forging processes with flat dies’,Tribol. Trans., 1995, 38, 663–671.
3.
JensenMRDamborgFFNielsenKBDanckertJ: ‘Applying the finite-element method for determination of tool wear in conventional deep-drawing’,J. Mater. Process. Technol., 1998, 83, 98–105.
4.
BeynonJH: ‘Tribology of hot metal forming’,Tribol. Int., 1998, 31, 73–77.
5.
JawaidAKoksalSSharifS: ‘Wear behavior of PVD and CVD coated carbide tools when face milling inconel 718’,Tribol. Trans., 2000, 43, 325–331.
6.
KimDHLeeHCKimBMKimKH: ‘Estimation of die service life against plastic deformation and wear during hot forging processes’,J. Mater. Process. Technol., 2005, 166, 372–380.
7.
TerčeljMSmolejAFajfarPTurkR: ‘Laboratory assessment of wear on nitrided surfaces of dies for hot extrusion of aluminium’,Tribol. Int., 2007, 40, 374–384.
8.
VergneCBoherCLevaillantCGrasR: ‘Analysis of the friction and wear behavior of hot work tool scale: application to the hot rolling process’,Wear, 2001, 250, 322–333.
9.
SkareTKrantzF: ‘Wear and frictional behaviour of high strength steel in stamping monitored by acoustic emission technique’,Wear, 2003, 255, 1471–1479.
10.
HanlonDNRainforthWM: ‘The rolling sliding wear response of conventionally processed and spray formed high speed steel at ambient and elevated temperature’,Wear, 2003, 255, 956–966.
11.
FoxMNSutcliffeMPF: ‘Modelling material transfer in metal rolling using plasticine’,Wear, 2008, 264, 18–25.
12.
PereiraMPYanWYRolfeBF: ‘Contact pressure evolution and its relation to wear in sheet metal forming’,Wear, 2008, 265, 1687–1699.
13.
LouaisilKDubarMDeltombeRDuboisADubarL: ‘Analysis of interface temperature, forward slip and lubricant influence on friction and wear in cold rolling’,Wear, 2009, 266, 119–128.
14.
HeinrichsJJacobsonS: ‘Laboratory test simulation of galling in cold forming of aluminium’,Wear, 2009, 267, 2278–2286.
15.
AbachiSAkkökMGöklerMİlhan: ‘Wear analysis of hot forging dies’,Tribol. Int., 2010, 43, 467–473.
16.
NairFKaramisMB: ‘An investigation of the tribological interaction between die damage and billet deformation during MMC extrusion’,Tribol. Int., 2010, 43, 347–355.
17.
OudinJRavalardYVerwaerdeGGelinJC: ‘Force, torque and plastic flow analysis in rotary upsetting of ring shaped billets’,Int. J. Mech. Sci., 1985, 27, 761–780.
18.
StandringPMMoonJRAppletonE: ‘Plastic deformation produced during indentation phase of rotary forging’,Met. Technol., 1980, 7, 159–166.
19.
ZhouDCYuanSJWangZRXiaoZR: ‘Defects caused in forming process of rotary forged parts and their preventive methods’,J. Mater. Process. Technol., 1992, 32, 471–479.
20.
WangGCGuanJZhaoGQ: ‘A photo-plastic experimental study on deformation of rotary forging a ring workpiece’,J. Mater. Process. Technol., 2005, 169, 108–114.
21.
WangGCXueKMLuY: ‘Methods of dealing with some problems in analyzing rotary forging with the FEM and initial application to a ring workpiece’,J. Mater. Process. Technol., 1997, 71, 299–304.
22.
YuanSJWangXHLiuGZhouDC: ‘The precision forming of pin parts by cold-drawing and rotary-forging’,J. Mater. Process. Technol., 1998, 86, 252–256.
23.
LiuGYuanSJWangZRZhouDC: ‘Explanation of the mushroom effect in the rotary forging of a cylinder’,J. Mater. Process. Technol., 2004, 151, 178–182.
24.
HuaLHanXH: ‘3D FE modeling simulation of cold rotary forging of a cylinder workpiece’,Mater. Des., 2009, 30, 2133–2142.
25.
HanXHHuaL: ‘Effect of size of the cylindrical workpiece on the cold rotary-forging process’,Mater. Des., 2009, 30, 2802–2812.
26.
HanXHHuaL: ‘Plastic deformation behaviors of cold rotary forging under different contact patterns by 3D elastic–plastic FE method’,Mater. Trans., 2009, 50, 1949–1958.
27.
HanXHHuaL: ‘3D FE modeling of cold rotary forging of a ring workpiece’,J. Mater. Process. Technol., 2009, 209, 5353–5362.
28.
HanXHHuaL: ‘Deformation characteristics and mechanisms of cold rotary forging of a ring workpiece’,J. Strain Anal. Eng. Des., 2010, 45, 97–114.
29.
HanXHHuaL: ‘Prediction of contact pressure, slip distance and wear in cold rotary forging using finite element methods’,Tribol. Int., 2011, 44, 1742–1753.
30.
ArchardJF: ‘Contact and rubbing of flat surfaces’,J. Appl. Phys., 1953, 24, 981–988.
31.
HsuSMShenMCRuffAW: ‘Wear prediction for metals’,Tribol. Int., 1997, 30, 377–383.
32.
PeiXHZhangMHuYM: ‘Rotary forging’; 1991, Beijing, Mechanical Industry Press.
