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Hot Forging Die Life Prediction Thesis 1 PRELIMINARY RESEARCH FOR THE DEVELOPMENT OF A HOT FORGING DIE LIFE PREDICTION MODEL A thesis presented to the faculty of the Fritz J. and Dolores H. Russ College of Engineering and Technology of Ohio University in partial fulfillment of the requirements for the degree Master of Science Thomas C. Grobaski August 2004 2 This thesis entitled PRELIMINARY RESEARCH FOR THE DEVELOPMENT OF A HOT FORGING DIE LIFE PREDICTION MODEL BY THOMAS GROBASKI has been approved for the Department of Mechanical Engineering and the Russ College of Engineering and Technology by Bhavin Mehta Professor of Mechanical Engineering Dennis Irwin Dean, Russ College of Engineering and Technology 3 Grobaski, Thomas C. M.S. August 2004. Mechanical Engineering PRELIMINARY RESEARCH FOR THE DEVELOPMENT OF A HOT FORGING DIE LIFE PREDICTION MODEL (119pp.) Director of Thesis: Bhavin Mehta ABSTRACT The goal of this research was to provide a preliminary step into developing a complete forging die life model. The research involved analyzing the initial effects of (1) friction, (2) work-piece temperature, (3) die temperature, and (4) forging press stroke speed on effective die stresses, die surface temperatures, die/work-piece sliding velocities, die/work-piece contact pressures, and die surface temperatures were examined. To obtain the results the forging process was modeled (SolidEdge 3D Solid Modeling Software), simulated (MSC.Superforge Software), and statistically setup and examined using two-level full factorial design of experiments (Analyzed with Minitab & MS. Excel). The product reviewed was a 10inch diameter differential ring gear forged at the American Axle Manufacturing, North Tonawanda, New York forging plant. The 4 ring gear is used in the rear differentials for Ford and GM trucks. Approved: Bhavin Mehta Professor of Mechanical Engineering 5 ACKNOWLEDGEMENTS First, I would like to thank my advisors for the help, guidance, and vision they provided when mine was blurriest. I wish the best of luck to you on all your future endeavors, and thank you for all your time and resources you graciously provided. Second, and foremost, I would like to thank my family and friends for keeping me sane, entertained, and grounded, while it was impossible to do so myself. Thank you for guiding and believing in me, I will never forget it (and I’m sure you’ll never let me). Finally, I would like to thank American Axle Manufacturing and their North Tonawanda Forge Facility for opening there doors and allowing access to there forge facility. A special thanks to Dr. Bamidele Oyekanmi and Matt Gersley for their time and cooperation. 6 TABLE OF CONTENTS Abstract...................................................3 Acknowledgements...........................................5 List of Figures ...........................................8 List of Tables............................................10 CHAPTER 1. Introduction...................................11 1.1 Problem Definition & Thesis Importance..........12 1.2 Research Objective..............................13 1.3 Process Modeling & Prediction...................14 1.4 Thesis Objective................................16 1.5 Thesis Overview.................................18 CHAPTER 2. Fundamentals of Forging........................19 2.1 Forging Today....................................20 2.2 Forging Processes................................22 2.2.1 Metal Forging Methods..........................23 2.2.2 Open Die Process...............................24 2.2.3 Impression Die Process.........................24 2.2.4 Forging at Various Temperatures................25 2.3 Forging Future...................................26 2.4 Importance of Die Life Prediction................27 CHAPTER 3. Die Failure Modes..............................28 3.1 Forging Die Wear Mechanisms......................31 3.1.1 Abrasive Wear Background.......................33 3.1.2 Adhesive Wear Background.......................36 3.1.3 Plastic Deformation............................37 3.1.4 Modeling Mathematically Abrasive & Adhesive Wear ..........................................38 3.1.4.1 Archard’s Wear Model.........................38 3.1.4.2 A Mathematical Approach to Wear..............39 3.1.4.3 Stahlberg & Hallstrom Local Energy Approach..41 3.1.4.4 Plastic Deformation Model....................41 3.2 Mechanical Fatigue...............................42 3.2.1 Stress-Life (S-N) Approach.....................44 3.2.2 Strain-Life Method.............................47 3.2.2.1 Coffin & Manson (Wöhler) Approach............47 3.2.2.2 Falk, Engel & Geiger’s Local Energy Approach.50 3.2.3 Fracture Mechanics Approach....................51 3.3 Catastrophic Failure.............................54 3.4 Thermo-mechanical Fatigue........................54 7 3.5 Overall Picture..................................57 CHAPTER 4. Forging Data & Outputs.........................58 4.1 Design of Experimentes...........................62 4.1.1 Factor Design Levels...........................62 4.1.1.1 Stroke Speed: High-Low Level................63 4.1.1.2 Work-piece Temperature: High-Low Level.......63 4.1.1.3 Die Temperature: High-Low Level..............64 4.1.1.4 Friction Factor: High-Low Level..............64 4.2 Design of Experiments............................64 4.2.1 Differential Ring Gear Specifications..........66 4.2.2 3D-Model Construction using SolidEdge..........68 4.2.3 MSC.Superforge Simulation Models Setup.........69 4.2.3.1 Modeled Material Properties..................72 4.2.3.2 Modeled Forging Press........................73 4.2.3.3 Modeled Friction at Interface................73 4.2.3.4 Modeled Thermal Dynamic Setup................74 4.2.3.5 Modeled Forming Process Setup ...............74 Chapter 5. Results........................................76 5.1 MSC.Superforge Buster Stage Outputs..............76 5.2 Validation of Results............................81 5.3 Statistical Analysis.............................82 5.3.1 Sliding Velocity: Normalized Plot & Analysis...86 5.3.2 Effective Stress: Normalized Plot & Analysis...87 5.3.3 Net Energy: Normalized Plot & Analysis.........89 5.3.4 Final Temperature of Surface: Normalized Plot & Analysis........................................91 5.3.5 Z-Load Force: Normalized Plot & Analysis.......93 5.3.6 Surface Contact Pressure: Normalized Plot & Analysis........................................95 5.4 Statistical Analysis Summation...................96 Chapter 6. Conclusion....................................98 6.1 Future Research & Recommendations................99 6.2 Finale..........................................100 References...............................................101 Appendix A: American Axle Forging Specifications.........105 Appendix B: MSC.Superforge Ring Gear Simulations.........106 Appendix C: Material Properties..........................109 Appendix D: Forging Press Velocity Curves................112 Appendix E: Taylor’s Tool Life Equation..................114 Appendix F: ANOVA Tables from Statistical Analysis.......115 8 LIST OF FIGURES Figure 1.1: Setup for Predicting Die Forging Life........17 Figure 2.1: Basic Forging Setup..........................22 Figure 3.1: Aspects of the Forging Process Design that Affect Wear and Fracture, Lange, K ..................29 Figure 3.2: Failure Modes and Basic Criteria.............30 Figure 3.3: Die Failure Mechanisms & Common Locations....31 Figure 3.4: Wear Mechanism’s and Mathematical Models.....32 Figure 3.5: Microscopic Wear Models......................34 Figure 3.6: A) Metallurgical Weld B) Adhesion Joint Adhesive Wear [26]...................................37 Figure 3.7: Stages of Fatigue Process, [23]..............43 Figure 3.8: Estimated S-N Curve (Whöler) for Steels......46 Figure 3.9: A) Universal Slopes B) Four Points - Coffin & Manson’s Graphical Fatigue [26]......................47 Figure 3.10: Wohler Curve for Strain Life Approach [7]...49 Figure 3.11: Crack Propagation [13]......................53 Figure 3.12: Basic Thermal Temperature Progress of Die...56 Figure 3.13: Thermo-mechanical Loading In-Phase [23].....56 Figure 4.1: SolidEdge Sketch for 3D Model Lower Die......58 Figure 4.2a to f: SolidEdge Dies .par Files .............69 Figure 4.3: Upper Die Blocker Stage, Isometric Position..70 Figure 4.4: Work-piece, Post Buster Stage ...............70 Figure 4.5: Lower Die Blocker Stage, Isometric Position..70 Figure 4.6: Aligned Forging Process Setup................71 Figure 4.7: Positioned (Front View, Transparent Dies)....72 Figure 4.8: Axisymmetric 2D Model of Forging Process.....75 Figure 5.1a & b: Initial & Final 2D Setup of Forging Process..............................................78 Figure 5.2: 2D Simulation Z-Force Load {lbs} on Upper Die..................................................78 Figure 5.3: 2D Simulation Maximum Final Temperature of Upper Die Surface {°F}...............................79 Figure 5.4: 2D Simulation of Net Energy Supplied by Upper Die {J}..............................................79 Figure 5.5: 2D Results: Max. Effective Stress {psi} in Upper Die............................................80 Figure 5.6: 2D Simulation of Maximum Sliding Velocity {in/s} at Upper Die and Work-piece Interface.........80 Figure 5.7: 2D Simulation of Maximum Contact Pressure {psi} at Upper Die and Work-piece Interface..........81 Figure 5.8: Normal Distribution Curve (α=.25)............83 9 Figure 5.9: Normal Probability Plot of the Effects for Sliding Velocity {in /s}.............................86 Figure 5.10: Normal Probability Plot
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