Prediction of wear in hot forging tools by means of finite-element-analysis

The intention of the work presented in this paper is the estimation of abrasive tool wear, as the major cause of failure of tools used for hot forging. Experiments are carried out to determine the wear amount after several numbers of forging cycles. For tool wear estimation, the analysed forging process in consideration of all process stages is represented with a finite-element model to compute the wear relevant parameters. A separate program is developed to calculate the tool wear by using the Archard wear model taking into account the hardness change of the tool surface layer with increasing number of forging cycles. In the end, the applied wear model is verified by comparing with the experimental results.