Failures of Tools and Dies

2021 ◽  
pp. 715-735
Author(s):  
George F. Vander Voort
Keyword(s):  
Heat Treatment ◽  
Cold Working ◽  
Mechanical Design ◽  
Failure Mechanisms ◽  
Hot Working ◽  
Manufacturing Processes ◽  
Tool Steels ◽  
Machining Processes ◽  
Number Of Factors ◽  
Die Materials

Abstract This article discusses failure mechanisms in tool and die materials that are very important to nearly all manufacturing processes. It is primarily devoted to failures of tool steels used in cold working and hot working applications. The processes involved in the analysis of tool and die failures are also covered. In addition, the article focuses on a number of factors that are responsible for tool and die failures, including mechanical design, grade selection, steel quality, machining processes, heat treatment operation, and tool and die setup.

Modelling and Experimental Investgations of Tooling Issues for Thixoforming of Steel

2019 ◽  
Vol 285 ◽  
pp. 347-353
Author(s):  
Ahmed Rassili
Keyword(s):  
Finite Elements ◽  
Failure Modes ◽  
Failure Mechanisms ◽  
Surface Treatments ◽  
Hot Working ◽  
Tool Steels ◽  
Tool Materials ◽  
Tool Coating ◽  
Experimental Trials

Since the early 90’s, and from the very early investigations of steel thixoforming, tool materials as well as different kinds of coatings, including different tool steels and fully ceramic systems have been evaluated. The failure mechanisms have been carefully investigated by experiments and simulations and are nearly fully understood. Analysis of the reported literature on this topic shows that there is still a lot to do in this field and no excellent solution exists now a days for steel thixoforming. The aim of this work is to evaluate the thermal and mechanical loadings applied to the tools during steel thixoforming process in order to determine appropriate tool materials and solutions. This evaluation was realized thanks to experimental trials and to the finite elements simulations. The effect of these loadings on the tool’s failure modes are highlighted and compared to the ones observed in classical forming processes. Beyond this, the failure modes of different tool materials and solutions are presented. The tested materials are hot-working tool steels. Other possibilities and tool coating or surface treatments are discussed as well.

ALUMINUM 3004

Alloy Digest ◽  
1974 ◽  
Vol 23 (4) ◽  
Keyword(s):  
Heat Treatment ◽  
Corrosion Resistance ◽  
Shear Strength ◽  
High Temperature ◽  
Magnesium Alloy ◽  
Cold Working ◽  
Heat Treating ◽  
Temperature Performance ◽  
Good Workability ◽  
Manganese Magnesium

Abstract ALUMINUM 3004 is nominally an aluminum-manganese-magnesium alloy which cannot be hardened by heat treatment; however, it can be strain hardened by cold working. It has higher strength than Aluminum 3003 and good workability, weldability and resistance to corrosion. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and compressive and shear strength as well as fatigue. It also includes information on low and high temperature performance, and corrosion resistance as well as forming, heat treating, machining, and joining. Filing Code: Al-51. Producer or source: Various aluminum companies. Originally published June 1957, revised April 1974.

Prediction of suitable heat treatment for H13 tool steels by application of thermal shock fatigue cycle

2021 ◽  
pp. 135065012110118
Author(s):  
Palani Karthikeyan ◽  
Sumit Pramanik
Keyword(s):  
Heat Treatment ◽  
Crack Initiation ◽  
Thermal Shock ◽  
Tool Steel ◽  
Treatment Method ◽  
Industrial Applications ◽  
Tool Steels ◽  
H13 Steel ◽  
H13 Tool Steel ◽  
Cyclic Treatment

In industry, thermally shocked components lead to early failures and unexpected breakdowns during production resulting in huge losses in profit. Thus, the present study investigates the as-received, hardened and hardened and nitrogen treated H13 tool steels subjected to a thermal shock gradient similar to the actual industrial applications. The thermal shock gradients were created by using an in-house-built thermal shock fatigue cyclic treatment machine. The effect of thermal shock fatigue cyclic treatments at 1000 and 2000 thermal shock cycles in hot and molten metal chambers was noticed. All the thermal shock fatigue cyclic-treated samples were analysed by hardness, X-ray diffraction, microscopy and magnetic tests. The interesting changes in hardness, distorted crystal structure and crack initiation were found to be different for differently treated H13 tool steel specimens. The molten aluminium was more prone to stick to the surface of as-received as well as hardened and nitrogen treated steel compared to the hardened H13 steel specimens, which would delay the crack initiation. The wear resistance properties of the hardened H13 steel specimens were found to be higher than as-received and hardened and nitrogen treated H13 steel specimens after thermal shock fatigue cyclic treatment. The loss in magnetic properties was significant for the hardened and hardened and nitrogen treated samples compared to as-received H13 tool steel specimens. Therefore, the present 1000 and 2000 thermal fatigue cycles for 30 s at 670 °C would be worthy to predict the proper heat treatment method to design the parameters as well as the life of die-casting components and to help in the economical production of casting.

Proving the Labeled Interval Calculus for Inferences on Catalogs

1990 ◽  
Author(s):  
Walid Habib ◽  
Allen C. Ward
Keyword(s):  
Mechanical Design ◽  
Formal System ◽  
Constraint Propagation ◽  
Operating Conditions ◽  
Manufacturing Processes ◽  
Entire System ◽  
High Level Language ◽  
Design Problems ◽  
High Level ◽  
Interval Constraint

Abstract The “labeled interval calculus” is a formal system that performs quantitative inferences about sets of artifacts under sets of operating conditions. It refines and extends the idea of interval constraint propagation, and has been used as the basis of a program called a “mechanical design compiler,” which provides the user with a “high level language” in which design problems for systems to be built of cataloged components can be quickly and easily formulated. The compiler then selects optimal combinations of catalog numbers. Previous work has tested the calculus empirically, but only parts of the calculus have been proven mathematically. This paper presents a new version of the calculus and shows how to extend the earlier proofs to prove the entire system. It formalizes the effects of toleranced manufacturing processes through the concept of a “selectable subset” of the artifacts under consideration. It demonstrates the utility of distinguishing between statements which are true for all artifacts under consideration, and statements which are merely true for some artifact in each selectable subset.

Thick Si-doped DLC coatings with high load bearing capacity on cold working tool steels by PECVD

2021 ◽  
pp. 1-19
Author(s):  
Xinyu Wang ◽  
Xudong Sui ◽  
Shuaituo Zhang ◽  
Mingming Yan ◽  
Yan Lu ◽  
...  
Keyword(s):  
Wear Resistance ◽  
Cold Working ◽  
Chemical Vapor ◽  
Tool Steels ◽  
Dlc Coatings ◽  
Wear Rates ◽  
Si Doped ◽  
Silicon Doped ◽  
Hydrogenated Amorphous ◽  
Degree Of Graphitization

Abstract For improving the wear resistance, thick silicon doped hydrogenated amorphous carbon (a-SiC:H) coatings were deposited on cold working tool steels by Plasma Enhanced Chemical Vapor Deposition (PECVD) technology. The increase of the acetylene (C2H2) flow rate distinctly tuned the microstructure of a-SiC:H coatings, including an increase in the coating thickness (>15 μm), a decrease in the silicon content, a greater sp2/sp3 ratio and higher degree of graphitization. The highest hardness of 19.61 GPa and the greatest critical load of 50.7 N were obtained. The coating showed low wear rates against different friction pairs and presented excellent abrasive wear resistance at high applied load and the wear rates decreased with increasing loads, which exhibited an outstanding application prospect in cold working tool steels.

scholarly journals PEMBENTUKAN MATERIAL (METAL FORMING) HOT WORKING PROCESS DAN COLD WORKING PROCESS

2019 ◽  
Author(s):  
Wahyu Hidayat
Keyword(s):  
Metal Forming ◽  
Cold Working ◽  
Hot Working ◽  
Working Process

1.Hot Working Process (Pengerjaan Dalam Kondisi Panas)Pada proses pengerjaan Hot Working Process ini akan terjadi kenaikan tegangan luluh, kenaikan nilai kekerasan material (logam baja), dan penurunan nilai keuletan material.2.Cold Working Process (Pengerjaan Dalam Kondisi Dingin) Proses pembentukan logam secara plastis dengan temperatur pengerjaan di bawah temperatur rekristalisasi.

scholarly journals Improving the Performance of Steel Machining Processes through Cutting by Vibration Control

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5712
Author(s):  
Mihaela Oleksik ◽  
Dan Dobrotă ◽  
Mădălin Tomescu ◽  
Valentin Petrescu
Keyword(s):  
Fourier Transformation ◽  
Vibration Analysis ◽  
Cutting Tool ◽  
Cutting Process ◽  
Manufacturing Processes ◽  
Machining Processes ◽  
Short Time ◽  
Short Time Fourier Transformation ◽  
Dynamic Phenomena

Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the improved construction version. In the first stage of the research, an analysis was made of the vibrations that appear in the cutting process when using the two types of tools. Vibration analysis considered the following: use of the Fast Fourier Transform (FFT) method, application of the Short-Time Fourier-Transformation (STFT) method, and observation of the acceleration of vibrations recorded during processing. After the vibration analysis, the roughness of the surfaces was measured and the parameter Ra was taken into account, but a series of diagrams were also drawn regarding the curved profiles, filtered profiles, and Abbott–Firestone curve. The research showed that use of the tool that is the improved constructive variant allows accentuated reduction of vibrations correlated with an improvement of the quality of the processed surfaces.

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