Study on investigation of hot forging die wear analysis – An industrial case study R. Rajiev a,⇑ , P. Sadagopan b , R. Shanmuga Prakash a a Department of Mechanical Engineering, Bannari Amman Institute of Technology, Sathyamangalam, India b Department of Production Engineering, PSG College of Technology, Coimbatore, India article info Article history: Received 16 August 2019 Received in revised form 14 November 2019 Accepted 27 November 2019 Available online xxxx Keywords: Hot forging Finite element analysis Pressure distribution Sliding velocities Wear analysis abstract Hot forging is a metal forming process mostly used in production industry. Hot forging dies are robustly affect by the stress increase during the hot forging process due to high temperature, plastic deformation of die and etc. In this study, wear analysis was carried out in AISI 316 stainless steel work piece material for pan head bolt component and EN19 work piece material for insert component and die were carried out in a local forging industry. The simulation of the forging process on the die and the work piece 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. Experimental study has been conducted for various die pre heating temperature and wear on die has been studied. Finally intensity of wear in hot forging die cavity was calculated using the Finite Element simulation and then the total wear depth was established. By using simulation results the total wear depths were estimated at different locality of the hot forging die cavity and finally max- imum significance of wear depth is attained. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods. 1. Introduction Forming operations, whose main purpose is to bring a change in shape, are very often used to perform a deliberate, controlled change in material properties, usually to obtain improved strength and ductility. Forging is defined as a process of manufacture by means of deformation in conjunction with heating, separating of a workpiece without permanent work hardening [1]. The service life of tools in metal forming processes which were limited to a large extent by wear, fracture and plastic deformation of the tools, etc. In hot-and-warm forging processes, amongst these factors, the 70% of tool life depends on wear [2]. In Hot forging 70% of die fail- ure will occur due to wear in the hot forging process. Erstwhile, the wear failures are due to thermal and mechanical cracks and plastic deformation [3]. To estimate the die service life in hot forging pro- cesses. One method can predict the plastic deformation of a die and the other one is for the die wear. The thermal softening of dies due to the local temperature rise, led to the reduction of the service life of hot forging dies by plastic deformation more than by abrasive wear [4]. Several researchers used wear models based on the Arch- ard’s wear model to calculate the die wear by taking into account the hardness loss due to the tempering of the die material with increasing number of forging cycles [5]. In industrial hot forging process, a new lubrication-cooling sys- tem has been developed to enable an investigation of the effect of lubrication on the tool wear [11]. Hot forging is one of the conven- tional metal-forming processes used in the production of critical parts in various industries. In hot forging process, the temperature rise in a die cavity and huge stresses generated during forging operation lead to die failure, which may be due to wear, deforma- tion, and cracking, etc. From the various literature studies on the die wear analysis in hot forging processes, it is found the factors that affect the die life are thermal fatigue, plastic deformation, abrasive tool wear and the thermal behavior on the hardness of die material. In this research work, the wear analysis was carried out in a hot forging die made of AISI H13 die steel that is used to forge a pan head bolt component made of stainless steel SS316. In another case, the wear study on the die made of AISI H13 die steel that is used to forge an insert component made of EN19 alloy steel in a local forging industry. The said actual die wears were compared with the simulation results using DEFORM software https://doi.org/10.1016/j.matpr.2019.11.330 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods. ⇑ Corresponding author. E-mail address: cheryuvaraj@gmail.com (R. Rajiev). Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr Please cite this article as: R. Rajiev, P. Sadagopan and R. Shanmuga Prakash, Study on investigation of hot forging die wear analysis – An industrial case study, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.330