TY - JOUR

T1 - Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

AU - Behrens, Bernd Arno

AU - Huskic, Aziz

AU - Rosenbusch, Daniel

AU - Peddinghaus, Julius

AU - Wester, Hendrik

AU - Siegmund, Martin

AU - Giedenbacher, Jochen

AU - Siring, Janina

N1 - Funding Information: Acknowledgments: The results presented in this paper were obtained within the research project “AVIF A318”. The authors thank the Research Association of the Working Group of the Iron-and Metal-processing Industry e.V. (AVIF) for their financial support of this project. Funding: This research was funded by the Research Association of the Working Group of the Iron-and Metal-processing Industry e.V. (AVIF), grant number A318.

PY - 2022/6/21

Y1 - 2022/6/21

N2 - Internal die cooling during forging can reduce thermal loads, counteracting surface sof-tening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel’s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.

AB - Internal die cooling during forging can reduce thermal loads, counteracting surface sof-tening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel’s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.

KW - die analysis

KW - die cooling

KW - finite element method

KW - hybrid-forging die

KW - laser powder bed fusion

KW - wear protection

UR - http://www.scopus.com/inward/record.url?scp=85132300612&partnerID=8YFLogxK

U2 - 10.3390/met12071063

DO - 10.3390/met12071063

M3 - Article

AN - SCOPUS:85132300612

VL - 12

JO - Metals

JF - Metals

SN - 2075-4701

IS - 7

M1 - 1063

ER -