Pan head bolt and insert component die wear analysis and investigation of surface finish of aluminium 6061 component using bio lubricants in hot forging

Abstract

One of the main critical problems in the hot forging process is the temperature rise in the die cavity and huge stresses generated during forging operation which leads to die failure due to wear deformation of a die cracks etc In this study wear analysis was carried out in a pan head bolt die and an insert die in a local industry The simulation of the forging process newlineon the die and the workpiece was carried out using commercially available software DEFORM The flow of the material in the die die filling contact pressure distribution sliding velocities and temperature distribution of the die have been investigated The depth of wear in the die cavity was evaluated using the Finite Element simulation and then the total wear depth was determined By comparing the numerical results with the measurement taken newlinefrom the worn die the wear coefficients were evaluated at different locations of the die cavity and finally an average value of wear coefficient is suggested In addition the effect of using different lubricants on the surface finish of aluminium alloy component was carried For a given aluminium alloy forging the pressure requirements in forging vary widely newlineand it depends primarily on the chemical composition of the alloy being forged the forging process employed the forging strain rate the lubrication and the workpiece and the newline die temperature newline newline newline