Procedure For Tool Life Improvement

COLT Design Manual for Cold Forging Dies Cyclic plasticity and low-cycle fatigue (1)
Procedure for tool life improvement

established within the European research project COLT
New materials Material testing Material modelling FE analysis Evaluation
Development of new Static tension and Numerical modelling of Analysis of the Localization of
PM tool steels with compression tests the cyclic stress-strain elastic-plastic the most critical
improved properties, response material response area of the die
Cyclic step tests
especially with in the die
regard to increased
fatigue strength Fatigue tests Determination of Calculation of the Estimation of
Whler curve and damage / energy die life until
damage parameters dissipation in the crack initiation
critical die area incl. life scatter
Optimization, e.g. by tool material,

prestress conditions, process design, etc.
Test of tool design in industrial production
Established within the GROWTH project GRD1-1999-10748 "Improvement of Service Life and Reliability of Cold Forging Tools
with respect to Fatigue Damage due to Cyclic Plasticity (COLT)", funded by the European Community.

Cyclic step tests
regard to increased

Uniaxial static and cyclic testing

of tool materials
Test equipment at the Risoe

National Laboratories, Denmark:
- High-stiffness servohydraulic
Test
universal test machine with
specimens
extremely rigid mounting
- Equipped with conventional
contact extensometer and
laser extensometer for
strain measurements
- Strain controlled testing
2002 by Ris National Laboratory, Denmark
Set-up for cyclic tests using laser extensometer
Recommended standard program

with static and cyclic tests
Standard program:
1 static tensile test
1 static compression test
2 cyclic step tests,
controlled by
laser extensometer
2 cyclic step tests to fracture,
controlled by
contact extensometer ASP23 at 62 HRc
Aim:
To get maximum information Youngs modulus, Poisson ratio
about static and cyclic
properties with a minimum 0.05%, 0.1% and 0.2% tensile yield stress
number of specimens stress-strain response under tension

Standard program:
controlled by
laser extensometer
controlled by
contact extensometer
ASP23 at 62 HRc
Youngs modulus, Poisson ratio

0.05%, 0.1% and 0.2% compressive yield stress
stress-strain response under compression

Standard program:
controlled by
laser extensometer
controlled by
contact extensometer
Stress response at different strain ranges and mean strains

Amount of cyclic plastic strains at different stress/strain ranges
Shape of cyclic stress-strain response at different strain ranges
Example for stress-strain response in cyclic step test

Step 4 - last cycle Step 5 - last cycle
Plastic strain range: 0.002% Plastic strain range: 0.019%
Step 6 - last cycle Step 7 - last cycle

before rupture
Plastic strain range: 0.062% Plastic strain range: 0.134%

Cyclic step tests
regard to increased

Advanced material model by Pedersen
The Pedersen model allows the

modelling of the stress-strain
response, taking into account:
- micro plasticity
- mean stress relaxation
- cyclic hardening / softening
- ratchetting
The parameters for the
Pedersen model are derived by
experimental procedures.
Principle cyclic stress-strain response (1 load cycle)

and its main characteristic parameters
mean strain Stress parameters:
stress range
stress
g prestress level
din
a stress at maximum process load
lo
stress range
stress at max.
process load
g
in
prestress level
ad
g
Strain parameters:
in
lo
un
ss
tre
strain range
es
pr
mean strain
cyclic plastic strains
cyclic plastic strain

strain
strain range
Energy based damage model according to M. Hnsel
The total work is defined as sum of elastic

and plastic energy:
W t W e W p
The Material tests within the COLT project
prove the relation between the amount of
energy and the fatigue life until crack
initiation.
Therefore, the number of cycles until

crack intiation can be increased by
- reducing/eliminating the amount of elastic
energy in the tensile regime (reducing We+)
- minimizing the amount of plastic strains
(thus reducing Wp)
STRECONs strategy to improve the fatigue life

by influencing the stress-strain response
Increased prestress level:
reduces or eliminates
the tensile stresses
But: the stress range
remains the same
Stress
Stress
Technical requirement:
increased loadability of
the prestressing system
provided by STRECON
prestressed container
STRECONs strategy to improve the fatigue life

by influencing the stress-strain response
Increased stiffness of the
prestressing system:
reduces or eliminates
the tensile stresses
reduces the stress
Stress
Stress
range
reduces the cyclic
plastic strains
Technical requirement:
high loadability and
stiffness of the
prestressing system
provided by STRECON
E+ prestressed container
Increased stiffness of the tooling system

by STRECON E+ containers
Model of a STRECON E+ prestressed container:
Winding core
made of tungsten carbide:
85-88 HRa, E = 540 GPa
provides increased stiffness of the
total tooling system
conical inner bore for assembly
of the die
casing
strip-winding
winding core

Strip-winding
provides the strength and controls casing
the prestress distribution
strip-winding
high-strength steel strip:
62-64 HRc, E = 210 GPa winding core
yield stress > 2000 MPa

Casing
fixes and covers the strip-winding
provides the interface
to the assembly in the press
cold- or hot-working steel
38-48 HRc, E = 210 GPa
casing
strip-winding
winding core

Cyclic step tests
regard to increased

Concept of load and loadability

with regard to tool performance
LOAD LOADABILITY PERFORMANCE
ON THE TOOL OF THE TOOL OF THE TOOL
dependent on MACRO- MICRO- characterized by

MATERIAL
type of process MECHANICAL STRUCTURAL mean life
STRENGTH
RESPONSE RESPONSE
part geometry dependent on dependent on dependent on standard
deviation
preform design tool geometry basic material material grade
structure reliability level
workpiece mat. mechanical chem. compos.
mat. properties phases accuracy
temperature production (expansion and
lubrication prestressing grain and method deformation)
system particle sizes
and others heat treatment and others
prestressing crack size and
hard coating
level type
and others and others and others

Procedure For Tool Life Improvement

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COLT Design Manual for Cold Forging Dies Cyclic plasticity and low-cycle fatigue (1)

Procedure for tool life improvement

Optimization, e.g. by tool material,

Test of tool design in industrial production

Procedure for tool life improvement

Optimization, e.g. by tool material,

Test of tool design in industrial production

Uniaxial static and cyclic testing

Test equipment at the Risoe

2002 by Ris National Laboratory, Denmark

Set-up for cyclic tests using laser extensometer

Recommended standard program

Recommended standard program

Youngs modulus, Poisson ratio

Recommended standard program

Stress response at different strain ranges and mean strains

Example for stress-strain response in cyclic step test

Plastic strain range: 0.002% Plastic strain range: 0.019%

Step 6 - last cycle Step 7 - last cycle

Plastic strain range: 0.062% Plastic strain range: 0.134%

Procedure for tool life improvement

Optimization, e.g. by tool material,

Test of tool design in industrial production

Advanced material model by Pedersen

The Pedersen model allows the

Principle cyclic stress-strain response (1 load cycle)

cyclic plastic strain

Energy based damage model according to M. Hnsel

The total work is defined as sum of elastic

Therefore, the number of cycles until

STRECONs strategy to improve the fatigue life

STRECONs strategy to improve the fatigue life

Increased stiffness of the tooling system

Increased stiffness of the tooling system

Increased stiffness of the tooling system

Procedure for tool life improvement

Optimization, e.g. by tool material,

Test of tool design in industrial production

Concept of load and loadability

dependent on MACRO- MICRO- characterized by

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