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...

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Autores principales:	Marek Hawryluk, Jacek Ziemba, Marta Janik, Piotr Górski, Łukasz Dudkiewicz, Kornelia Głód, Jakub Krawczyk
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	valve forging durability of forging punch wear of calotte area numerical modelling Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
Acceso en línea:	https://doaj.org/article/aa2af14c123c4806b15e49527e70d411
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id	oai:doaj.org-article:aa2af14c123c4806b15e49527e70d411
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spelling	oai:doaj.org-article:aa2af14c123c4806b15e49527e70d4112021-11-25T18:16:03ZWear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging10.3390/ma142270631996-1944https://doaj.org/article/aa2af14c123c4806b15e49527e70d4112021-11-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/22/7063https://doaj.org/toc/1996-1944The 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.Marek HawrylukJacek ZiembaMarta JanikPiotr GórskiŁukasz DudkiewiczKornelia GłódJakub KrawczykMDPI AGarticlevalve forgingdurability of forging punchwear of calotte areanumerical modellingTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 7063, p 7063 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	valve forging durability of forging punch wear of calotte area numerical modelling Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	valve forging durability of forging punch wear of calotte area numerical modelling Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 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
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.
format	article
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
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_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_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_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
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/aa2af14c123c4806b15e49527e70d411
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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

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