SARDAR VALLABHBHAI PATEL INSTITUTE

OF TECHNOLOGY

INCREASING TOOL LIFE OF HOT FORGING

TOOL BY REDUCING WEAR

RESEARCH AND IPR

(3710001)

PREPARED BY : PANCHAL BHAVESHKUMAR P. (180410708002)

GUIDED BY : Dr. P V RAMANA (Head of the Department)

RESEARCH PAPER - 1
1. TITLE OF RESEARCH PAPER REVIEW OF SELECTED METHODS OF
INCREASING THE LIFE OF FORGING
TOOLS IN HOT DIE FORGING PROCESS

2. JOUNAL NAME ARCHIVES OF CIVIL AND

MECHANICAL ENGINEERING

3. AUTHORS MAREK HAWRYLUK

4. VOLUME, ISSUE VOLUME 16, ISSUE 4

5. PAGES 845-866

6. YEAR SEP, 2016

DEPARTMENT OF
2
MECHANICAL ENGINEERING
1.1 INTRODUCTION
• The work concerns the possibilities of applying
various methods with the purpose to increase the
life of forging tools, which, based on the experience
and research of the author, realized in cooperation
with the forging industry, exhibit the highest
effectiveness in improving the life of forging tools.
• The presented investigation results refer to:
selection of the tool material for a particular
process, its adequate thermal and thermo-chemical
treatment, use of surface engineering techniques:
hybrid with the use of coatings applied physically
from the gaseous phase, use preventive pad
welding, as well as optimization of the die shape
and construction of the instrumentation set.
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1.2 MATERIALS AND
METHODOLOGY USED

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Table 1 shows the approximate chemical composition,
thermal treatment and hardness of tool alloy steels for hot
operations.

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1.3 RESULTS

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1.4 CONCLUSION
• By way of developing the presented directions of
improving the tool life and applying a series of
methods, such as: physical and numerical MES
modelling, as well as many other computer-aided
tools, it is possible to solve many problems
connected with the short tool life. Further research
in this direction and the continuous development of
technology should contribute to the resolution of the
discussed issues and improve the quality of the
manufactured products as well as increase the
production efficiency.

DEPARTMENT OF MECHANICAL ENGINEERING 9

RESEARCH PAPER - 2
1. TITLE OF RESEARCH PAPER ANALYSIS OF THE WEAR OF FORGING
TOOLS SURFACE LAYER AFTER
HYBRID SURFACE TREATMENT

2. JOUNAL NAME INTERNATIONAL JOURNAL OF

MACHINE TOOLS & MANUFACTURE

3. AUTHORS MAREK HAWRYLUKA

4. VOLUME VOLUME 114

5. PAGES 60-71

6. YEAR MARCH, 2017

DEPARTMENT OF
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MECHANICAL ENGINEERING
2.1 INTRODUCTION
• In this paper the analysis concerned the manner of wear
of the hybrid layers and their resistance to specific
degradation mechanisms.

• Three different coatings were applied: AlCrTiSiN,

Cr/CrN and AlCrTiN.

• Based on the performed studies, it was possible to select

the most optimal hybrid layer, which allows one to
improve tool life.

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11
2.2 MATERIALS AND
METHODOLOGY USED
• Three different coatings were applied: AlCrTiSiN,
Cr/CrN and AlCrTiN.
• The coatings were tested on 19 tools, and 3
representatives for each coating were selected,
followed by their through research analysis.
• The process of forging a lid forging was selected
realized on the crank press P-1800T (ram stroke:
280 mm, nbr of strokes/min: 70), nominal force 18
MN, in three forging operations; upsetting,
roughing and finishing forging.

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• The elements were forged from steel C45, from billets
with the dimensions: φ=55 cm, l=95 mm and weight
1,77 kg. The temperature of the charge material equaled
1150 °C. The tools are preheated to a temperature of
around 250 °C.
• Tools in the analyzed process are made of WCL steel
(1.2343). After the heat treatment tools used in the
second and third operations are subjected to nitriding
after which have a hardness of the surface layer at the
level of 1100–1150 HV.
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• The process of a multi-step hybrid treatment of the
analyzed tools was performed in three stages.
• stage I – vacuum thermal treatment of the steel
substrate,
• stage II – creation of the nitrided layer by the ion
nitriding method,
• stage III – processes of deposition of selected
PVD coatings.
• A detailed complex analysis was performed of
selected areas of the working surface of each tool
by the following research techniques:
• Optical Microscopy
• Scanning electron microscopy
• Microhardness HV 0.1 measurements
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2.3 RESULTS
• The preliminary results showed that the best effects
for the whole tool working surface were obtained
for the Cr/CrN layer, characterizing in high
adhesion as well as the lowest Young's modulus E
and hardness.
• In the case of high tool forces and the related
friction, the best results were obtained for the
AlCrTiN coating, which, beside its good adhesion
properties, also characterizes in the highest abrasive
wear resistance.

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2.4 CONCLUSION
• Among the applied coatings the highest resistance is
characterized by coating CrN and AlCrTiN, can
therefore be used for tools for hot forging in order
to improve their durability.
• Nitrided tool wear out faster compared to the
covered coating, since the start of operation there is
abrasive wear, and oxidation of the nitrided layer,
leading to its damage or removal – a PVD coatings
protect nitrided layer.
• AlCrTiSiN coating is not suitable for use in forging
tools because it is not fatigue resistant and thermal-
mechanical easily goes to chipping.
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• CrN coating is the most resistant to fatigue, as it
exhibits a strong adhesion to the substrate and a
lower hardness than the other layers.
• AlCrTiN coating is resistant to abrasive wear but
due to the high hardness and the strong internal
cohesion of the coating is susceptible to creation
and propagation of large and deep cracks, which
lowers its fatigue resistance.
• The proposed method of reverse 3D scanning
enables efficient evaluation of the progress of tools
wear and detection of sudden damage to the surface
layer.

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RESEARCH PAPER - 3
1. TITLE OF RESEARCH PAPER
2. JOUNAL NAME
IMPROVEMENT OF THE WEAR
RESISTANCE OF HOT FORGING DIES
USING A LOCALLY SELECTIVE
DEPOSITION TECHNOLOGY WITH
TRANSITION LAYERS
CIRP ANNALS - MANUFACTURING
TECHNOLOGY

3. AUTHORS DONG-GYU AHN

4. VOLUME, ISSUE VOLUME 65, ISSUE 1

5. PAGES 257-260

6. YEAR 2016

DEPARTMENT OF
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MECHANICAL ENGINEERING
3.1 INTRODUCTION

• A locally selective deposition technology with

transition layers using a direct energy deposition
process is investigated to improve the wear
resistance of hot forging dies.

• A transition layer between the deposited region and

the substrate is created to reduce mechanical and
thermal problems as a buffer in interface regions.

DEPARTMENT OF MECHANICAL ENGINEERING 19

3.2 MATERIALS AND
METHODOLOGY USED
• Design data of transition layers are obtained from
experiments.
• Numerical analyses have been performed for
deposited regions of dies.
• The DED process fabricates parts via line byline
deposition of beads. The beads are created from a
laser cladding process using a coaxial nozzle. The
proposed technology creates the TL between the
deposited layer and the substrate to reduce the
thermal fatigue induced by differences of thermal
properties.

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3.3 RESULTS
• From the hot forging experiment, it has been shown that the
proposed locally selective deposition technology with a
buffer layer can help to dramatically improve the wear
resistance of hot forging dies.

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3.4 CONCLUSION

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RESEARCH PAPER - 4
1. TITLE OF RESEARCH PAPER
2. JOUNAL NAME
INFLUENCE OF THE APPLICATION OF
A PN+CR/CRN HYBRID LAYER ON THE
IMPROVEMENT OF THE LIFETIME OF
HOT FORGING TOOLS
JOURNAL OF MATERIALS
PROCESSING TECHNOLOGY

3. AUTHORS MAREK HAWRYLUK

4. VOLUME VOLUME 258

5. PAGES 226-238

6. YEAR AUGUEST, 2018

DEPARTMENT OF
24
MECHANICAL ENGINEERING
4.1 INTRODUCTION
• This paper presents the results of field tests
performed on forging tools in a selected lid hot
forging process.
• The aim of the studies was to increase the durability
of hot forging tools.
• Different coating types dedicated to hot forging
tools were proposed and first tested in laboratory
conditions. Based on the laboratory test results, the
PN+Cr/CrN hybrid layer was selected to improve
tool durability.

DEPARTMENT OF MECHANICAL ENGINEERING 25

4.2 MATERIALS AND
METHODOLOGY USED
• The hybrid layer was produced on a plasma-nitrided
substrate, onto which a PVD Cr/CrN coating was
deposited.
• All the analyzed tools were tested in industrial
conditions through the manufacturing of specific
quantities of forgings.
• Tools (upper punches used in second forging
operation) with a PN+Cr/CrN layer applied on them
were tested in comparison with gas-nitrided tools.

DEPARTMENT OF MECHANICAL ENGINEERING 26

• The wear of each tool was analyzed by surface
scanning and then compared to the CAD model.
• All the tools were checked for changes in the
surface layer under an optical and a scanning
electron microscope, as well as by way of a micro
hardness measurement.
• The studies were divided into two stages. The first
stage covered observations and comprehensive
tests of the coatings under laboratory conditions.
The second stage of studies concerned industrial
tests conducted under hot forging conditions.

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4.3 RESULTS

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• Based on the conducted tests and obtained results,
the Cr/CrN coating was selected as the most
suitable for the application on forging tools.
• The application of a PVD coating, besides just
nitriding, which forms a hybrid layer together with
the nitrided layer, clearly results in an
improvement of lifetime.
• The application of a hybrid layer with the Cr/CrN
coating contributed to extending tool lifetime by
restraining the progress of individual destructive
phenomena that occur at different times and at
different intensities over the course of the hot
forging process.
DEPARTMENT OF MECHANICAL ENGINEERING 31
4.4 CONCLUSION
• The hybrid layer with a Cr / CrN coating exhibited
abrasive wear resistance but was weakened by the
tempering of the surface layer under the coating.
Therefore, it is proposed to increase its thickness to
enhance the thermal barrier effect. On the basis of the
results obtained and other studies conducted by the
authors of this manuscript, it is recommended to carry
out tests on Cr/CrN and similar coatings, which will be
able to maintain adhesion to the substrate despite their
greater thickness. In addition, the surface of the
substrate should be adequately prepared to allow
adhesion of the coating to the substrate, but also to
provide a low roughness of the substrate, so that the
coating has a uniform thickness and a smooth surface.
DEPARTMENT OF MECHANICAL ENGINEERING 32
• The beneficial properties of hybrid layers will
continue to be researched for the purpose of
improving tool lifetimes and can successfully be
applied to forging tools, particularly tools for
precision forging, where high dimensional
accuracy of the forgings is expected. What is more,
this type of coating can be used in many different
cases of hot forging tools, where the problem of
low durability occurs, with the exception of
punches used in precision forging because of the
extreme shear stresses present in the surface layer.

DEPARTMENT OF MECHANICAL ENGINEERING 33

RESEARCH PAPER -5
1. TITLE OF RESEARCH PAPER
2. JOUNAL NAME
OPTIMIZED PLASMA NITRIDING
PROCESSES FOR EFFICIENT WEAR
REDUCTION OF FORGING DIES
ARCHIVES OF CIVIL AND
MECHANICAL ENGINEERING

3. AUTHORS H. PASCHKE

4. VOLUME, ISSUE VOLUME 12, ISSUE 4

5. PAGES 407-412

6. YEAR DECEMBER, 2012

DEPARTMENT OF
34
MECHANICAL ENGINEERING
5.1 INTRODUCTION

• This paper presents the influence of main process

parameters on the wear behavior of dies.
• The focused steel material of this work is DIN-
X38CrMoV5-1 (1.2343), a standard hot forming
tool steel.
• The influence of nitriding parameters like
temperature, nitrogen flow and time on the nitriding
depth, hardness and crack sensitivity has been
investigated.

DEPARTMENT OF MECHANICAL ENGINEERING 35

5.2 MATERIALS AND
METHODOLOGY USED
• Forging dies and testing samples were made of DIN-
X38CrMoV51(1.2343) hot forming tool steel with a
composition of C=0.39%, Cr=5.30%, Mo=1.30%,
andV¼0.40%. This standard material in the hot forging
industry was used for the specimens and manufactured
tools for forging and industrial field tests. All specimens
and tools were hardened to 4872 HRC.
• Process parameters were: temperature 520/560 ̊C,
treatment time 16h, pressure 350Pa, voltage 500V, duty
cycle (pulse duty factor) of D=0.25 and D=0.17 (i.e.
pulse/pulse pause 100/300 or 100/500 ms/ms). Used
gases were nitrogen (10or80% of total flow) and
hydrogen.
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5.3 RESULTS

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• Nitriding with low intensity is promoting the
formation of few but deep cracks which lead to
severe cracking of bigger parts in the surface zone
with continued forging process.
• A qualitatively better surface by means of cracking
and abrasive activity is achieved with an intensive
nitriding with high nitrogen contents in treatment
atmosphere and more intensive plasma activation.
• Tools treated at 560 ̊C for16h at 10% nitrogen in
atmosphere and low nitriding intensity are showing
less crack sensitivity by means of the crack depth
but even wider cracks. Compared to tools treated
under same temperature conditions with intensive
nitriding conditions.
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5.4 CONCLUSION

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THANK YOU