Die Life Extension Using Tribology Technology Numpon Mahayotsanun - PowerPoint PPT Presentation

Die Life Extension Using Tribology Technology Numpon Mahayotsanun THAI TRIBOLOGY ASSOCIATION (TTA)

Automotive Industry Trends Fuel Economy Safety Surface Quality Energy (Reduced Friction) Low Density and High Strength Superior Surface Finish page 2 THAI TRIBOLOGY ASSOCIATION (TTA)

Short Die Life Problems Energy (Reduced Friction) Low Density and High Strength Superior Surface Finish Increased Load/Stress Increased Die Damage (Wear) Short Die Life page 3 THAI TRIBOLOGY ASSOCIATION (TTA)

Auto Parts Manufacturing Processes Rolling Stamping Punching Forging Source: (1) www.custompartnet.com, (2) www.whtildesley.com page 4 THAI TRIBOLOGY ASSOCIATION (TTA)

Die Damage Problems Rolling Stamping Punching Forging Source: www.sciencedirect.com page 5 THAI TRIBOLOGY ASSOCIATION (TTA)

Die Damage and Related Properties Damage Related Die Properties Sheet Forming Process • Wear • Anti-fmaking (for surface coatings) • Galling (Seizure) • Oxidation resistance • Flaking • Surface structure • Deformation • Hardness • Compression strength • Fracture • Toughness • Chipping • Heatcheck • Fatigue strength • Thermal fatigue strength 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. page 6 THAI TRIBOLOGY ASSOCIATION (TTA)

Die Damage and Related Properties Damage Related Die Properties Hot Forging Process • Wear • Anti-fmaking (for surface coatings) • Galling (Seizure) • Oxidation resistance • Flaking • Surface structure • Deformation • Hardness • Compression strength • Fracture • Toughness • Chipping • Heatcheck • Fatigue strength • Thermal fatigue strength 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. page 7 THAI TRIBOLOGY ASSOCIATION (TTA)

What is Tribology? Energy Waste Reduction “Tribo” = “Rubbing” Interacting Surfaces Multidisciplinary F N • Mechanical Engineering v • Friction • Materials Science • Surface Technology Service Life Extension • Wear Counter body • Chemistry • Biology • Lubrication • Nano Technology Base body Savings Source: Mang T, Bobzin K, Bartels T. Industrial Tribology: Tribosystems, Wear and Surface Engineering, Lubrication. John Wiley & Sons; 2011. page 8 THAI TRIBOLOGY ASSOCIATION (TTA)

Tribology of Die Die (Material and Coating) F N v Workpiece (Material Properties) Die Key Considerations Lube Lubrication (Lubricant Properties) Workpiece Condition (Pressure, Temperature, Velocity, etc.) page 9 THAI TRIBOLOGY ASSOCIATION (TTA)

Die Life Improvement Countermeasure Plan Deterioration of Strength Deterioration of Accuracy Step I - Die Life Criterion Defjnition Inferior Apperance Many Surface Defects Deveation from Accuracy Standard Change in Shape Step II - Die Damage Observation Breakage Surface Roughening Plastic Deformation Wear Step III - Die Damage Causes Adhesion Adhesive Wear Abrasive Wear Fatigue Wear Overload Fatigue Step IV - Die Damage Causes Solving Excessive Thermal Load Severe Forming Conditions Large Alternating Stress Step V - Countermeasure Plan Higher Strength Tool Materials Higher Toughness Tool Materials Improvement of Lubrication Surface Hardening Surface Treatment Strengthening of Base Material Step VI - Die Damage Causes Check Adhesive Strength Compatibility with Toughness Hardness of Coating Film 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. page 10 THAI TRIBOLOGY ASSOCIATION (TTA)

Example Solution Coating 50,000 Parts 1,200,000 Parts Source: www.thefabricator.com page 11 THAI TRIBOLOGY ASSOCIATION (TTA)

Coated Tools A 20% reduction in manufacturing time Longer gives 15% saving per part. (Extended tool life -> fewer replacements) Faster This is due to a less time on machinery (High speed -> increased production) and staffjng. Harder If a company produces the same quan- (Ability to cut or form harder materials) 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- Cheaper timized solution. (Less lubricants -> materials saving) Source: Ian Taylor and Prof. Robert Wood, The Scale of Tribology and Associated Cost Savings page 12 THAI TRIBOLOGY ASSOCIATION (TTA)

Key Improvements Material Properties Die Base Material Increased Toughness (Heat Treatment) Operating Condition Surface Engineering Die Coating Increased Strength (Coating & Texturing) Lubricant Lubricants Selection Reduced Friction & Heat (Type & Viscosity) Workpiece Optimized Condition Process Parameters Adjustment page 13 THAI TRIBOLOGY ASSOCIATION (TTA)

Design and Selection Material Properties (Heat Treatment) Tribology Knowledge (Friction, Wear, Lubrication) Design Surface Engineering (Die, Process) (Coating & Texturing) Tribology Testing (Tribometers) Lubricants Selection (Type & Viscosity) Selection (Material, Lubricant, Coating) Die Wear/Life Prediction (Theories, FEA) Process Parameters Adjustment page 14 THAI TRIBOLOGY ASSOCIATION (TTA)

Thai Tribology Association (TTA) Research & Development Tribology Knowledge (Friction, Wear, Lubrication) Design (Die, Process) Tribology Training Tribology Testing (Tribometers) Selection Networking (Material, Lubricant, Coating) Die Wear/Life Prediction (Theories, FEA) page 15 THAI TRIBOLOGY ASSOCIATION (TTA)

Thai Tribology Association (TTA) Research & Development Tribology Training Networking page 16 THAI TRIBOLOGY ASSOCIATION (TTA)

Numpon Mahayotsanun Vice President Thai Tribology Association (TTA) 131 Thailand Science Park, INC 1 Bldg., Room 234 Phahonyothin Road, Khlong Nueng Khlonh Luang, Pathumthani 12120 Thailand Email. numpon@kku.ac.th www.tta.or.th THAI TRIBOLOGY ASSOCIATION (TTA)