This article was initially published with incorrect copyright information. Upon publication of th... more This article was initially published with incorrect copyright information. Upon publication of this Correction, the copyright of this article changed to "The Author(s)". The original article has been corrected.
Additive Manufacturing (AM) technologies are providing exciting opportunities for repair and rema... more Additive Manufacturing (AM) technologies are providing exciting opportunities for repair and remanufacture of industrial components. Laser Metal Deposition with powder (LMD-p) is an ideal candidate process for selective remanufacture of high value tools and dies exhibiting wear, particularly on complex geometries found in hot forging applications. When used in combination with a multi-axis CNC machining centre and a suitable metal powder metallurgy, LMD-p can produce hybrid (additive/subtractive) remanufacturing operations which exceed the original wear characteristics of production die sets. DigiTool, a consortium funded project by Innovate UK, consisting of the Advanced Forming Research Centre (AFRC) and five industrial partners, developed a remanufacturing process for complex closed die tooling geometry. After careful consideration of commercially available metal powders in the range 40 to 120 µm for use with LMD‑p, MetcoClad 21, a cobalt based hard-facing alloy, was selected as the metal powder repair medium due to its superior sliding wear resistance, galling, and machinability. Experimental trials determined the optimum LMD-p process parameters and worn H13 tool steel hot forging dies were successfully remanufactured along the complex flash land areas and pocket features in the cavity. The selective die repairs were subsequently verified in a production environment at the customer site, resulting in die life increase of 108% whilst maintaining all dimensional and customer quality standards. The die life increase has allowed the customer to reduce the piece-part cost and win the business back from a competitor.
Additive Layer Manufacturing (ALM) processes are attracting interest in the forging industry due ... more Additive Layer Manufacturing (ALM) processes are attracting interest in the forging industry due to their potential suitability for remanufacturing and repair of tools and dies. The ALM process known as Laser Metal Deposition with powder (LMD-p) can be used to provide a hard-facing alloy repair to hot forging tools. This is particularly important on complex tool geometries due their superior wear resistance. The Advanced Forming Research Centre (AFRC) has established a low cost standard test method to evaluate abrasive and adhesive wear on hot forging H13 tool steel dies on an industrial scale 160 kJ Schuler screw press. The bespoke tool design allows researchers to benchmark new and novel coatings, lubricants and additive layers against a known standard. Furthermore, AFRC metrology standard methods ensure repeatability and reproducibility of benchmark results. To evaluate the performance of LMD-p for remanufacturing of hot forging tools and dies, a cobalt based alloy (Stellite 21 ®) was selected. Stellite 21 ® is widely used as a hard-facing alloy as it provides excellent machinability coupled with superior wear characteristics. AFRC standard dies were coated with LMD-p Stellite 21 ®. The LMD-p coating was then machined to final geometry and then subjected to hot forging under AFRC standard conditions to compare to benchmark wear characteristics. Adhesive and abrasive wear was evaluated. It was shown that the Stellite 21 ® LMD-p additive layer performed better in both adhesive and abrasive conditions than standard H13 tools steel dies.
Di e wear, which is defined as a surface damage or removal of material from one or both of two s ... more Di e wear, which is defined as a surface damage or removal of material from one or both of two s olid surfaces in a s l iding, rolling or impact motion relative to one a nother, is considered the main cause of tool failure. Wear i s res pons i bl e for 70% of tool failure and a potential s ource of high costs; a s much as 30% per forging uni t i n the forgi ng i ndus tri es [1]. Thi s paper presents a unique wear prediction and measurement method for open di e forgi ng us i ng a modi fi ed Archa rd equation, 3D FE simulation (to represent the a ctual forging process precisel y) a nd a n i ndus tri a l s ca l e forgi ng tri a l. The proposed tool and experimental design is aimed at facilitating a cost effective method of tool wear a nalysis and to establish a repeatable method of measurement .It creates a platform to test different type of lubricants and coatings on i ndus tri a l s ca le environment. The forging tri al was ca rried out using 2100T Schuler Screw pres s. A full factorial experiment design was us ed on 3D simulation to identify the process setting for creating a measurable amount of tool wea r. Wea r predi cti on of 28.5 μm ba s ed on the simulation correlated wi th both Infi ni te Focus Opti ca l Mi cros cope a nd Coordi na te Mea s uri ng Ma chi ne (CMM) measurement results of the practical trial. Thermal ca mera reading showed temperature raise o n the a rea wi th ma xi mum wea r, whi ch s ugges ts tha t i ncrea s e i n conta ct ti me, ca us es therma l s ofteni ng on tool s teel. The mea surement s howed that a brasive wear and adhesive wear a re dominant failure modes on the tool under thes e proces s condi ti ons .
This article was initially published with incorrect copyright information. Upon publication of th... more This article was initially published with incorrect copyright information. Upon publication of this Correction, the copyright of this article changed to "The Author(s)". The original article has been corrected.
Additive Manufacturing (AM) technologies are providing exciting opportunities for repair and rema... more Additive Manufacturing (AM) technologies are providing exciting opportunities for repair and remanufacture of industrial components. Laser Metal Deposition with powder (LMD-p) is an ideal candidate process for selective remanufacture of high value tools and dies exhibiting wear, particularly on complex geometries found in hot forging applications. When used in combination with a multi-axis CNC machining centre and a suitable metal powder metallurgy, LMD-p can produce hybrid (additive/subtractive) remanufacturing operations which exceed the original wear characteristics of production die sets. DigiTool, a consortium funded project by Innovate UK, consisting of the Advanced Forming Research Centre (AFRC) and five industrial partners, developed a remanufacturing process for complex closed die tooling geometry. After careful consideration of commercially available metal powders in the range 40 to 120 µm for use with LMD‑p, MetcoClad 21, a cobalt based hard-facing alloy, was selected as the metal powder repair medium due to its superior sliding wear resistance, galling, and machinability. Experimental trials determined the optimum LMD-p process parameters and worn H13 tool steel hot forging dies were successfully remanufactured along the complex flash land areas and pocket features in the cavity. The selective die repairs were subsequently verified in a production environment at the customer site, resulting in die life increase of 108% whilst maintaining all dimensional and customer quality standards. The die life increase has allowed the customer to reduce the piece-part cost and win the business back from a competitor.
Additive Layer Manufacturing (ALM) processes are attracting interest in the forging industry due ... more Additive Layer Manufacturing (ALM) processes are attracting interest in the forging industry due to their potential suitability for remanufacturing and repair of tools and dies. The ALM process known as Laser Metal Deposition with powder (LMD-p) can be used to provide a hard-facing alloy repair to hot forging tools. This is particularly important on complex tool geometries due their superior wear resistance. The Advanced Forming Research Centre (AFRC) has established a low cost standard test method to evaluate abrasive and adhesive wear on hot forging H13 tool steel dies on an industrial scale 160 kJ Schuler screw press. The bespoke tool design allows researchers to benchmark new and novel coatings, lubricants and additive layers against a known standard. Furthermore, AFRC metrology standard methods ensure repeatability and reproducibility of benchmark results. To evaluate the performance of LMD-p for remanufacturing of hot forging tools and dies, a cobalt based alloy (Stellite 21 ®) was selected. Stellite 21 ® is widely used as a hard-facing alloy as it provides excellent machinability coupled with superior wear characteristics. AFRC standard dies were coated with LMD-p Stellite 21 ®. The LMD-p coating was then machined to final geometry and then subjected to hot forging under AFRC standard conditions to compare to benchmark wear characteristics. Adhesive and abrasive wear was evaluated. It was shown that the Stellite 21 ® LMD-p additive layer performed better in both adhesive and abrasive conditions than standard H13 tools steel dies.
Di e wear, which is defined as a surface damage or removal of material from one or both of two s ... more Di e wear, which is defined as a surface damage or removal of material from one or both of two s olid surfaces in a s l iding, rolling or impact motion relative to one a nother, is considered the main cause of tool failure. Wear i s res pons i bl e for 70% of tool failure and a potential s ource of high costs; a s much as 30% per forging uni t i n the forgi ng i ndus tri es [1]. Thi s paper presents a unique wear prediction and measurement method for open di e forgi ng us i ng a modi fi ed Archa rd equation, 3D FE simulation (to represent the a ctual forging process precisel y) a nd a n i ndus tri a l s ca l e forgi ng tri a l. The proposed tool and experimental design is aimed at facilitating a cost effective method of tool wear a nalysis and to establish a repeatable method of measurement .It creates a platform to test different type of lubricants and coatings on i ndus tri a l s ca le environment. The forging tri al was ca rried out using 2100T Schuler Screw pres s. A full factorial experiment design was us ed on 3D simulation to identify the process setting for creating a measurable amount of tool wea r. Wea r predi cti on of 28.5 μm ba s ed on the simulation correlated wi th both Infi ni te Focus Opti ca l Mi cros cope a nd Coordi na te Mea s uri ng Ma chi ne (CMM) measurement results of the practical trial. Thermal ca mera reading showed temperature raise o n the a rea wi th ma xi mum wea r, whi ch s ugges ts tha t i ncrea s e i n conta ct ti me, ca us es therma l s ofteni ng on tool s teel. The mea surement s howed that a brasive wear and adhesive wear a re dominant failure modes on the tool under thes e proces s condi ti ons .
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