19th International Metallurgy & Materials Congress (IMMC 2018), İstanbul, Turkey, 25 - 27 October 2018, pp.845-848
Hot forging process is a conventional method used for metal forming to meet the demands for lower production costs and shorter times. Forging die is an important part for the hot forging industry. Hot forging dies are exposed to wear and fatigue owing to being continuously under thermal effects and cyclic mechanical loads. Failures of these components leads to serious problems in terms of expected service life of the die and therefore manufacturing cost of the product. Most of the hot forging dies failures are caused due to inadequacy of die materials, die design, die manufacturing or forging operations. Insufficient forging ratio, insufficient cleanliness and heat treatment of the dies, small corner radius, shortage of the die width and thickness, inadequate surface treatment, weld reparation of the die surface, insufficient pre-heating, inadequate die face and lubrication are the major factors that lead to failure of the hot forging dies that are used in the metal forming process. In this study, main types of damages on industrial upper and lower hot forging dies for the hot forging operations and reasons of these mentioned above failures were investigated and evaluated by visually inspecting several different samples. Solutions were also suggested for the each hot forging die failure case.
Keywords: Hot forging die, Failure analysis, Visual inspection.