Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

authored by: Bernd Arno Behrens, Aziz Huskic, Daniel Rosenbusch, Julius Peddinghaus, Hendrik Wester, Martin Siegmund, Jochen Giedenbacher, Janina Siring
Abstract: Internal die cooling during forging can reduce thermal loads, counteracting surface sof-tening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel’s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Upper Austria University of Applied Sciences
Type: Article
Journal: Metals
Volume: 12
ISSN: 2075-4701
Publication date: 21.06.2022
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all), Metals and Alloys
Electronic version(s): https://doi.org/10.3390/met12071063 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{87648598bcd44389ab5724e7f2859b69,
title = "Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels",
abstract = "Internal die cooling during forging can reduce thermal loads, counteracting surface sof-tening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel{\textquoteright}s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.",
keywords = "die analysis, die cooling, finite element method, hybrid-forging die, laser powder bed fusion, wear protection",
author = "Behrens, {Bernd Arno} and Aziz Huskic and Daniel Rosenbusch and Julius Peddinghaus and Hendrik Wester and Martin Siegmund and Jochen Giedenbacher and Janina Siring",
note = "Funding Information: Acknowledgments: The results presented in this paper were obtained within the research project “AVIF A318”. The authors thank the Research Association of the Working Group of the Iron-and Metal-processing Industry e.V. (AVIF) for their financial support of this project. Funding: This research was funded by the Research Association of the Working Group of the Iron-and Metal-processing Industry e.V. (AVIF), grant number A318. ",
year = "2022",
month = jun,
day = "21",
doi = "10.3390/met12071063",
language = "English",
volume = "12",
journal = "Metals",
issn = "2075-4701",
publisher = "Multidisciplinary Digital Publishing Institute",
number = "7",
}