Die Life Extension UsingTribology Technology

THAI TRIBOLOGY ASSOCIATION (TTA)

Numpon Mahayotsanun

THAI TRIBOLOGY ASSOCIATION (TTA) page 2

Automotive Industry Trends

Fuel Economy Safety Surface Quality

Energy (Reduced Friction) Low Density and High Strength Superior Surface Finish

Superior Surface FinishLow Density and High Strength

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Short Die Life Problems

Energy (Reduced Friction)

Increased Load/Stress

Increased Die Damage (Wear)

Short Die Life

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Auto Parts Manufacturing Processes

Rolling Stamping Punching Forging

Source: (1) www.custompartnet.com, (2) www.whtildesley.com

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Die Damage Problems

Rolling Stamping Punching Forging

Source: www.sciencedirect.com

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Die Damage and Related PropertiesRelated Die Properties

Source: Yoshinari Tsuchiya, Trend in Process Tribology Focusing on Die Life - Key Technology for Precise and Efficient Production, R&D Review of Toyota CRDL, Vol. 34, No. 4.

DamageSheet Forming Process

• Wear

• Galling (Seizure)

• Flaking

• Deformation

• Anti-flaking (for surface coatings)

• Oxidation resistance

• Surface structure

• Hardness

• Compression strength

• Toughness

• Fatigue strength

• Thermal fatigue strength

• Fracture

• Chipping

• Heatcheck

THAI TRIBOLOGY ASSOCIATION (TTA) page 7

Die Damage and Related PropertiesRelated Die Properties

Source: Yoshinari Tsuchiya, Trend in Process Tribology Focusing on Die Life - Key Technology for Precise and Efficient Production, R&D Review of Toyota CRDL, Vol. 34, No. 4.

DamageHot Forging Process

• Wear

• Galling (Seizure)

• Flaking

• Deformation

• Anti-flaking (for surface coatings)

• Oxidation resistance

• Surface structure

• Hardness

• Compression strength

• Toughness

• Fatigue strength

• Thermal fatigue strength

• Fracture

• Chipping

• Heatcheck

THAI TRIBOLOGY ASSOCIATION (TTA) page 8

What is Tribology?

Source: Mang T, Bobzin K, Bartels T. Industrial Tribology: Tribosystems, Wear and Surface Engineering, Lubrication. John Wiley & Sons; 2011.

Counter body

Base body

v

FN

“Tribo” = “Rubbing” Interacting Surfaces Multidisciplinary

• Mechanical Engineering• Materials Science• Surface Technology• Chemistry• Biology• Nano Technology

• Friction• Wear• Lubrication

Energy Waste Reduction

Service Life Extension

Savings

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Tribology of Die

Die

Workpiece

v

FN

Lube

Key Considerations

Die(Material and Coating)

Workpiece(Material Properties)

Lubrication(Lubricant Properties)

Condition(Pressure, Temperature, Velocity, etc.)

THAI TRIBOLOGY ASSOCIATION (TTA) page 10

Die Life ImprovementCountermeasure Plan

Step I - Die Life Criterion Definition

Step II - Die Damage Observation

Step III - Die Damage Causes

Step IV - Die Damage Causes Solving

Step V - Countermeasure Plan

Step VI - Die Damage Causes Check

Inferior Apperance Deterioration of AccuracyDeveation from Accuracy Standard

Surface Roughening Plastic Deformation Wear Breakage

Adhesive Wear Abrasive Wear Fatigue OverloadFatigue WearAdhesion

Excessive Thermal Load Large Alternating StressSevere Forming Conditions

Higher Strength Tool Materials Higher Toughness Tool MaterialsImprovement of Lubrication

Surface HardeningSurface TreatmentAdhesive Strength

Hardness of Coating Film

Strengthening of Base MaterialCompatibility with Toughness

Deterioration of StrengthMany Surface Defects

Change in Shape

Source: Yoshinari Tsuchiya, Trend in Process Tribology Focusing on Die Life - Key Technology for Precise and Efficient Production, R&D Review of Toyota CRDL, Vol. 34, No. 4.

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Example Solution

Source: www.thefabricator.com

50,000 Parts 1,200,000 PartsCoating

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Coated Tools

Source: Ian Taylor and Prof. Robert Wood, The Scale of Tribology and Associated Cost Savings

Faster(High speed -> increased production)

Harder(Ability to cut or form harder materials)

Cheaper(Less lubricants -> materials saving)

Longer(Extended tool life -> fewer replacements)

A 20% reduction in manufacturing time gives 15% saving per part.

This is due to a less time on machinery and staffing.

If a company produces the same quan-tity of parts, but 6 times faster, with tools that survive 4 times longer it can deliver a saving of 75% compared to an un-op-timized solution.

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Key Improvements

Increased ToughnessDie Base Material

Die Coating

Workpiece

Lubricant

Material Properties (Heat Treatment)

Increased Strength Surface Engineering (Coating & Texturing)

Reduced Friction & Heat Lubricants Selection(Type & Viscosity)

Optimized Condition Process Parameters Adjustment

Ope

ratin

g C

ondi

tion

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Design and Selection

Tribology Knowledge(Friction, Wear, Lubrication)

Material Properties (Heat Treatment)

Tribology Testing(Tribometers)

Surface Engineering (Coating & Texturing)

Die Wear/Life Prediction(Theories, FEA)

Lubricants Selection(Type & Viscosity)Selection

(Material, Lubricant, Coating)

Process Parameters Adjustment

Design(Die, Process)

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Thai Tribology Association (TTA)

Tribology Knowledge(Friction, Wear, Lubrication)

Tribology Testing(Tribometers)

Die Wear/Life Prediction(Theories, FEA)

Selection(Material, Lubricant, Coating)

Design(Die, Process)

Research & Development

Tribology Training

Networking

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Thai Tribology Association (TTA)

Research & Development

Tribology Training

Networking

Numpon MahayotsanunVice PresidentThai Tribology Association (TTA)131 Thailand Science Park,INC 1 Bldg., Room 234Phahonyothin Road, Khlong NuengKhlonh Luang, Pathumthani 12120 ThailandEmail. numpon@kku.ac.th

www.tta.or.th

THAI TRIBOLOGY ASSOCIATION (TTA)