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Analysis of Hot Forging Die Failure Modes
Applied to HOT FORGING MOLD
Types of Damage and Proportion
Causes
Countermeasures
Process Management
Thermal Fatigue cracking 40%
1.Repeated heating and cooling of the mold surface.
2.Thermal fatigue tensile stress Generation.
3.Grain boundary degradation due to high-temperature oxidation.
4.Crack propagation due to tip effect.
5.High temperatures cause a decrease in Cr (chromium) content.
6. High temperatures reduce the hardness of the die.
1.Mold surface temperature control.
2.Selection of steel with high rigidity and toughness.
3.Heat treatment ensuring high toughness quality.
4.Low-hardness diffusion- type nitriding treatment.
5.Surface lubrication and cooling conditions.
1.Mold cooling design.
2.Steel material.
3.Heat treatment.
4.Forging process.
5.Diffusion-type Nitriding treatment.
6.Selection and application of lubricant.
Abrasive Wear 15%
1.Intermetallic friction between the mold and the workpiece material.
2.Varying friction forces at different parts due to mold geometry.
3.Mold softening caused by high temperatures.
1.Reduce and disperse frictional pressure.
2.Select steel with high-temperature resistance.
3.Increase mold hardness.
4.Enhance surface hardness of the mold.
1.Mold shape design.
2.Steel material.
3.Heat treatment.
4. Surface treatment.
5.Selection and application of lubricant.
Plastic Deformation
15%
1.Insufficient mold strength under high temperature and high pressure.
2.Reduced yield strength of the mold at high temperatures.
1.Reduce and disperse frictional pressure.
2.Use steel resistant to high-temperature softening.
1.Mold shape design.
2.Steel material.
Seizure 8%
1.Adhesion phenomena caused by high-temperature contact between metals.
2.Surface roughening and peeling on the mold.
1.Improve mold surface smoothness.
2.Lower mold surface temperature.
3.Reduce and disperse frictional pressure.
1.Mold surface roughness.
2.Mold cooling design.
3.Selection and application of lubricant.
Die Fracture 12%
1.Excessive impact force or stress concentration.
1.Review mold structural strength.
2.Perform mold stress analysis.
3.Apply heat treatment to ensure high toughness.
1.Mold design.
2.Simulation and analysis of destructive stress.
3.Heat treatment.