Details
| Original language | English |
|---|---|
| Title of host publication | METAL 2020 - 29th International Conference on Metallurgy and Materials, Conference Proceedings |
| Pages | 320-326 |
| Number of pages | 7 |
| ISBN (electronic) | 9788087294970 |
| Publication status | Published - 27 Jul 2020 |
| Event | 29th International Conference on Metallurgy and Materials, METAL 2020 - Brno, Czech Republic Duration: 20 May 2020 → 22 May 2020 |
Publication series
| Name | METAL Conference Proceedings |
|---|---|
| ISSN (electronic) | 2694-9296 |
Abstract
The approach of the most common industry-specific FE-systems for the service life evaluation of forming tools holds some disadvantages. For example, within the decoupled tool analysis, load situations are typically analysed at room temperature and thus, the transient temperature development in the forging die is not considered in the lifetime evaluation. An elastic material behaviour is assumed for the tool component to be analysed. In this way, both deformation and fatigue behaviour are only approximately simulated. However, plastic deformation can occur in critical areas of the tool due to the operationally high tool loads, which can increase during operation and lead to hardening or softening processes in the material. For this reason, neglecting the temperature distribution in the tool makes it impossible to reproduce thermally induced damage processes. Therefore, Sehitoglu's life prediction approach, which is able to take into account thermo-mechanical loads in the tool during thixoforging and to calculate tool life, is presented in this publication. Since, particularly in thixoforming, where the temperatures exceed those of hot forming, the consideration of thermally induced damage plays a decisive role in order to predict the possibly early failure of the tools. Thus, an appropriate numerical design is possible. For this purpose, experimental tests such as low cycle and thermo-mechanical fatigue tests were performed for the parameterisation of the model. By means of optimisation routines, the model's parameters were determined. Subsequently, FE-simulations of a cup backward extrusion process were carried out to calculate tool fatigue along with different damage proportions. Finally, validation of the numerical calculations took place by a comparison with experimental results.
Keywords
- Fatigue model, FEA, Process simulation, Thixoforming, Tool life
ASJC Scopus subject areas
- Engineering(all)
- Mechanics of Materials
- Materials Science(all)
- Metals and Alloys
- Materials Science(all)
- Surfaces, Coatings and Films
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METAL 2020 - 29th International Conference on Metallurgy and Materials, Conference Proceedings. 2020. p. 320-326 (METAL Conference Proceedings).
Research output: Chapter in book/report/conference proceeding › Conference contribution › Research › peer review
}
TY - GEN
T1 - Numerical Service Life Calculation Of Forming Tools During Thixoforging Using The Sehitoglu Model
AU - Behrens, Bernd Arno
AU - Brunotte, Kai
AU - Wester, Hendrik
AU - Zaitsev, Alexander
AU - Hootak, Maiwand
N1 - Funding information: Sincere thanks to the German Research Foundation (DFG) for financial support (project number 299534929: “Numerical Calculation of Thermal Die Load and Die Life during Thixoforging of Steel”).
PY - 2020/7/27
Y1 - 2020/7/27
N2 - The approach of the most common industry-specific FE-systems for the service life evaluation of forming tools holds some disadvantages. For example, within the decoupled tool analysis, load situations are typically analysed at room temperature and thus, the transient temperature development in the forging die is not considered in the lifetime evaluation. An elastic material behaviour is assumed for the tool component to be analysed. In this way, both deformation and fatigue behaviour are only approximately simulated. However, plastic deformation can occur in critical areas of the tool due to the operationally high tool loads, which can increase during operation and lead to hardening or softening processes in the material. For this reason, neglecting the temperature distribution in the tool makes it impossible to reproduce thermally induced damage processes. Therefore, Sehitoglu's life prediction approach, which is able to take into account thermo-mechanical loads in the tool during thixoforging and to calculate tool life, is presented in this publication. Since, particularly in thixoforming, where the temperatures exceed those of hot forming, the consideration of thermally induced damage plays a decisive role in order to predict the possibly early failure of the tools. Thus, an appropriate numerical design is possible. For this purpose, experimental tests such as low cycle and thermo-mechanical fatigue tests were performed for the parameterisation of the model. By means of optimisation routines, the model's parameters were determined. Subsequently, FE-simulations of a cup backward extrusion process were carried out to calculate tool fatigue along with different damage proportions. Finally, validation of the numerical calculations took place by a comparison with experimental results.
AB - The approach of the most common industry-specific FE-systems for the service life evaluation of forming tools holds some disadvantages. For example, within the decoupled tool analysis, load situations are typically analysed at room temperature and thus, the transient temperature development in the forging die is not considered in the lifetime evaluation. An elastic material behaviour is assumed for the tool component to be analysed. In this way, both deformation and fatigue behaviour are only approximately simulated. However, plastic deformation can occur in critical areas of the tool due to the operationally high tool loads, which can increase during operation and lead to hardening or softening processes in the material. For this reason, neglecting the temperature distribution in the tool makes it impossible to reproduce thermally induced damage processes. Therefore, Sehitoglu's life prediction approach, which is able to take into account thermo-mechanical loads in the tool during thixoforging and to calculate tool life, is presented in this publication. Since, particularly in thixoforming, where the temperatures exceed those of hot forming, the consideration of thermally induced damage plays a decisive role in order to predict the possibly early failure of the tools. Thus, an appropriate numerical design is possible. For this purpose, experimental tests such as low cycle and thermo-mechanical fatigue tests were performed for the parameterisation of the model. By means of optimisation routines, the model's parameters were determined. Subsequently, FE-simulations of a cup backward extrusion process were carried out to calculate tool fatigue along with different damage proportions. Finally, validation of the numerical calculations took place by a comparison with experimental results.
KW - Fatigue model
KW - FEA
KW - Process simulation
KW - Thixoforming
KW - Tool life
UR - http://www.scopus.com/inward/record.url?scp=85096795599&partnerID=8YFLogxK
U2 - 10.37904/metal.2020.3484
DO - 10.37904/metal.2020.3484
M3 - Conference contribution
AN - SCOPUS:85096795599
T3 - METAL Conference Proceedings
SP - 320
EP - 326
BT - METAL 2020 - 29th International Conference on Metallurgy and Materials, Conference Proceedings
T2 - 29th International Conference on Metallurgy and Materials, METAL 2020
Y2 - 20 May 2020 through 22 May 2020
ER -