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| BİRÇOK YÜKLEME YAPTIM FAKAT HALA PUAN GELMEDİ.
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Dosyanın icerige de bu
ACKNOWLEDGEMENTS. III
NOMENCLATURE. VI
LIST OF TABLES. VII
LIST OF FIGURES. IX
1. INTRODUCTION. 1
2. PREVIOUS STUDIES. 5
2.1. Forging Processes. 5
2.2. Forging Machines. 6
2.2.1. Drop Hammers. 7
2.2.1.1 Gravity Drop Hammers. 7
2.2.1.2. Power Drop Hammers. 7
2.2.2. Mechanical Presses. 8
2.3. Classification of Forging Processes. 9
2.3.1. Open Die Forging. 9
2.3.2. Precision Forging. 10
2.3.3. Closed die Forging. 12
2.4. Forging Material. 14
2.5. Forging Dies. 15
2.5.1. Die Materials for Hot Forging. 15
2.5.1.1 Requirements for Die Materials. 17
2.5.2. Die Life. 20
2.5.2.1 Effect of Part Shape on Die Life. 22
2.5.2.2 Effect of Die Design on Die Life. 23
2.5.2.3 Effect of Temperature on Die Life. 24
2.5.2.4 Effect of Heat Treatment of Die Materials
on Die life. 25
2.5.2.5 Effect of Lubrication on Die Life. 29
2.5.3. Surface Treatments. 30
2.5.3.1 Plasma – Nitriding ( İon Nitriding). 31
2.5.3.2 Gas Nitriding. 33
2.5.3.3 Salt Bath Nitriding. 34
2.5.3.4 Nitrocarburizing. 36
2.5.3.5 Single Layer and Duplex Surface Coatings. 40
2.5.3.6 Weld Overlay Coating. 43
2.6 Evaluation of Literature Survey. 46
3. MATERIAL AND METHOD. 48
3.1 Material. 48
3.1.1 Forging Equipment. 48
3.1.2 Billet Heating Equipment. 49
3.1.3 Forging Dies. 52
3.1.3.1 Nitrided Dies. 55
IV
3.1.3.2 AlTiN coating. 55
3.1.3.3 Multilayer coating TOKTEK. 56
3.1.3.4 Weld overlay Coating with CASTOLIN N9080
Welding Electrode. 56
3.1.4 Billet Material. 58
3.1.5 Welding Equipment. 59
3.1.6 Die Lubricant. 59
3.1.7 Measuring Equipment. 61
3.2 Method. 61
3.2.1 Forging Procedure. 61
3.2.2 Die Service Life. 64
3.2.3 Die Cost Per Forged Part. 65
3.2.4 Break Even Point. 68
4. RESULT AND DISCUSSION. 70
4.1 Increase in Die Service Life. 71
4.1.1 Nitrided Dies. 71
4.1.2 AlTiN Coated Dies. 75
4.1.3 TOKTEK Coated Dies. 78
4.1.4 Weld Overlay Coated Dies. 81
4.2 Die Cost per Part. 85
4.2.1 As received Dies. 86
4.2.2 Nitrided Dies. 86
4.2.3 AlTiN coated Dies. 87
4.2.4 TOKTEK coated Dies. 88
4.2.5 Weld Overlay coated Dies. 89
4.3 Break Even Point. 92
4.3.1 Nitrided Dies. 92
4.3.2 AlTiN Coated Dies. 93
4.3.3 TOKTEK Coated Dies. 94
4.3.4 Weld Overlay Coated Dies. 94
5 - CONCLUSION AND FUTURE STUDİES. 96
5.1 Conclusion……………………………………………. 96
5.2 Future Studies…………………………………………. 98
REFERENCES. 99
CURRİCULUM VITAE. 104
V
NOMENCLATURE
(Cdie) The cost of the raw die material
(Csaw) The cost of sawing of the die materials
(Cmach) The cost of turning and milling of the dies
(CS.treat) The cost of surface treatment
(Cpress) The cost of the break of the forging press due to die polishing
(Cres ) Cost of resinking and reproduction with the same dies until the
life of the surface treatment has been finished.
( PFtot) Total forged parts
(Cprof+lab) The profit, including the cost of pre - paid direct and indirect
labor, that can be made from the production, that could be
made in the time of break due to die polishing and die
exchange of the forging press
(CDini) The total initial cost of the dies
(Cph) Cost of one hour of press break
(Clabh) Cost of one hour of direct and indirect labor
k Number of press breaks
(CDparts forged) Die cost Per part
VI
LIST OF TABLES
Table2.1 Table 2.1 Classification of alloys in order of increasing
forging difficulty. 14
Table 2.2 Chemical composition of tool and die material for hot
forging. 16
Table 2.3 Chemical composition of 47CrMoWVTiCeZr16-26-8 and
X40CrMoV5-1 tool steels. 26
Table 2.4 Nitriding Methods, Materials, and Characteristics of
Diffusion Layer. 36
Table 2.5 Thickness of the coatings. 41
Table 3.1 Technical properties of BRET PM 250. 49
Table 3.2 Technical input and output values of the induction
heater. 50
Table 3.3 The average values of pH, conductivity and Hardness of the
deionized water used in the closed circuit and at the output
of this induction heater. 52
Table 3.4 Chemical Composition of DIN 1.2344 hot work tool steel. 52
Table 3.5 Current values used for different electrode diameters in
welding method A and B. 58
Table 3.6 The chemical composition of the welding electrode
CASTOLIN N9080. 58
Table 3.7 Chemical composition of the billet material. 59
Table 3.8 The technical specification of the electric arc welding
machine. 59
Table 3.9 Physical properties of Acheson Deltaforge 144 die
lubricant (as supplied). 60
Table 3.10 Shearing / Cutting Work Instruction. 62
Table 3.11 “Part Inspection Instruction Sheet” for the part studied in this
work. 65
Table 4.1 Polishing life of nitrided dies during the forging Process. 72
Table 4.2 Polishing life of as received dies during the forging process. 72
Table 4.3 The deviations measured on critical dimensions of the as
received dies (Die Material DIN 1.2344;hardened and
tempered to a hardness of 45 HRC). 73
Table 4.4 The deviations measured on critical dimensions of the
nitrided dies (nitrided layer thickness : 0.3 mm;
hardness 63 HRC ). 73
