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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

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: Hawryluk, Marek, Ziemba, Jacek, Janik, Marta, Górski, Piotr, Dudkiewicz, Łukasz, Głód, Kornelia, Krawczyk, Jakub
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8624634/
https://www.ncbi.nlm.nih.gov/pubmed/34832461
http://dx.doi.org/10.3390/ma14227063
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author Hawryluk, Marek
Ziemba, Jacek
Janik, Marta
Górski, Piotr
Dudkiewicz, Łukasz
Głód, Kornelia
Krawczyk, Jakub
author_facet Hawryluk, Marek
Ziemba, Jacek
Janik, Marta
Górski, Piotr
Dudkiewicz, Łukasz
Głód, Kornelia
Krawczyk, Jakub
author_sort Hawryluk, Marek
collection PubMed
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.
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spelling pubmed-86246342021-11-27 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 Hawryluk, Marek Ziemba, Jacek Janik, Marta Górski, Piotr Dudkiewicz, Łukasz Głód, Kornelia Krawczyk, Jakub Materials (Basel) Article 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. MDPI 2021-11-21 /pmc/articles/PMC8624634/ /pubmed/34832461 http://dx.doi.org/10.3390/ma14227063 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Hawryluk, Marek
Ziemba, Jacek
Janik, Marta
Górski, Piotr
Dudkiewicz, Łukasz
Głód, Kornelia
Krawczyk, Jakub
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 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 Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8624634/
https://www.ncbi.nlm.nih.gov/pubmed/34832461
http://dx.doi.org/10.3390/ma14227063
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