Skip to main content
Log in

Improvement of surface integrity of cold forging tools by adaption of tool making process

  • Tooling
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Cold forging enables mass production of steel based components. High loads within cold forging presuppose high loadable tool materials. This is why apart from tool steels cemented carbides are mainly used as tool materials. Due to brittleness of these materials, fatigue is one of the major limits of tool life. Tool manufacturing requires a combination of hard machining and subsequent machining steps. For hard machining of complex tool geometries electrical discharge machining (EDM) represents the industrial standard. The thermal influenced surface layer has to be removed by post and fine machining steps. The resulting surface integrity has a major influence on the internal strength of a tool. Correlations between tool manufacturing, surface properties and tool behavior will gain knowledge for an optimized tool production. In this context, scope of the present paper are the investigation and description of the interactions between tool manufacturing and resulting surface properties for tools made of cemented carbide and tool steel. Within the article, the surface properties caused by a conventional process chain consisting of EDM and polishing are quantified. In addition, these results are compared to an adapted process chain with an integrated peening process. The results reveal that the conventional and the adapted process chain lead to similar surface topographies and roughness values. However, the integration of a peening process shifts the residual stress level towards higher compressive stresses.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Lange K, Kammerer M, Pöhlandt K, Schöck J (2008) Fließpressen. Springer, Berlin

    Book  Google Scholar 

  2. Engel U (1996) Beanspruchung und Beanspruchbarkeit von Werkzeugen der Massivumformung. Meisenbach, Bamberg

    Google Scholar 

  3. Andreas K, Merklein M, Engel U (2013) Fatigue behavior of cemented carbide based forming tools. In: Proceedings of the 18th Plansee Seminar, Reutte (in print)

  4. ICFG-Document (2004) Tool life & tool quality in cold forging—Part 2. International Cold Forging Group (ICFG), Doc. 16/04. Meisenbach, Bamberg

  5. Ekmekci B (2007) Residual stresses and white layer in electrical discharge machining (EDM). Appl Surf Sci 23:9234–9240

    Article  Google Scholar 

  6. ICFG-Document (2013) Tool life & tool quality in cold forging—Part 5. International Cold Forging Group (ICFG), Doc. 23/13. Meisenbach, Bamberg

  7. De Chiffre L, Christiansen S, Skade S (1994) Advantages and industrial applications of three-dimensional surface roughness analysis. Ann CIRP 43(1):473–478

    Article  Google Scholar 

  8. Geiger M, Engel U, Pfestorf M (1997) New developments for the qualification of technical surfaces in forming processes. Ann CIRP 46(1):171–174

    Article  Google Scholar 

  9. Kloos KH (1979) Residual stresses, definition and causes of generation. Z Werkstofftech 10:293–302

    Article  Google Scholar 

  10. Klaasen H, Kübarsepp J (2004) Wear of advanced cemented carbides for metal forming tool materials. Wear 256:846–853

    Article  Google Scholar 

  11. Weibull W (1939) A statistical theory of the strength of materials. Academy of Engineering Sciences in Sweden, Doc. 151, Stockholm

  12. ICFG-Document (1982) General aspects of tool design and tool materials for cold and warm forging. International Cold Forging Group (ICFG), Doc. 4/82. Meisenbach, Bamberg

  13. VDI-Richtlinie (1997) Werkstoffe für Kaltfließpresswerkzeuge. Verein Deutscher Ingenieure (VDI), VDI 3186, Blatt 2. Beuth, Düsseldorf

  14. Datasheet, Company Kennametal AMSG GmbH (2009) Chemische und physikalische Daten der Hartmetallsorten für Verschleißteile

  15. DatasheetVanadis 30, Company Uddeholm. www.uddeholm.de. Accessed 01 Mar 2007

  16. Kunieda M, Lauwers B, Rajurkar KP, Schumacher BM (2005) Advancing EDM through fundamental insight into the process. Ann CIRP 54(2):64–87

    Article  Google Scholar 

  17. Pfeiffer W, Wenzel J (2010) Shot peening of brittle materials—status and outlook. Mater Sci Forum 638–642:799–804

    Article  Google Scholar 

  18. Klocke F, Dambon O, Behrens B (2011) Analysis of defect mechanisms in polishing of tool steels. Prod Eng Res Dev. doi:10.1007/s11740-011-0301-6

    Google Scholar 

  19. Merklein M, Andreas K, Engel U (2011) Influence of machining process on residual stresses in the surface of cemented carbides. Procedia Eng 19:252–257

    Article  Google Scholar 

  20. Klocke F, König W (2007) Fertigungsverfahren 3—Abtragen, Generieren. Lasermaterialbearbeitung, Springer

    Google Scholar 

  21. Wohlfahrt H (1984) The influence of peening conditions on the resulting distribution of residual stress. In: Proceedings of 2nd International Conference on Shot Peening, Chicago, pp 316–331

Download references

Acknowledgments

The authors would like to thank the Bavarian Research Foundation for their financial support of the research project BFS 1001–11. Furthermore, the authors acknowledge the tool manufacturer FRANK Formenbau for machining the specimens as well as the companies Richard Bergner and ThyssenKrupp Presta for scientifically discussion.

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Marion Merklein.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Andreas, K., Merklein, M. Improvement of surface integrity of cold forging tools by adaption of tool making process. Prod. Eng. Res. Devel. 8, 131–141 (2014). https://doi.org/10.1007/s11740-013-0522-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-013-0522-y

Keywords

Navigation