Scholarlink

<p>This study investigates the root causes of premature die failures in the hot forging process of top cup used for modular scaffolding systems through experimental and numerical analysis. Results identify thermal fatigue, stress concentrations, and machining defects as primary failure mechanisms. Metallurgical characterization of W302 and W500 tool steels confirms standard material properties and proper heat treatment, eliminating these as failure causes. The finite element analysis (FEA) correlates simulated stress distributions (peaking at 925 MPa tensile and − 1037 MPa compressive) with observed crack initiation sites at some zones. The study demonstrates that machining defects and cyclic thermal loading significantly reduce die lifespan. By validating simulation results against physical die inspections, this work provides insights for optimizing die design, material selection, and machining processes to enhance durability and operational efficiency in hot forging applications.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Investigation of Failure Mechanisms in Hot Forging Dies for Top Cup Production

  • 期刊论文

  • 发表日期：

    2025年9月1日

查看全文
  • I. El-Mahallawi,
  • A. Shaker,
  • M. M. A. Abdellatif,
  • M. Boghdady,
  • S. Salem

摘要

This study investigates the root causes of premature die failures in the hot forging process of top cup used for modular scaffolding systems through experimental and numerical analysis. Results identify thermal fatigue, stress concentrations, and machining defects as primary failure mechanisms. Metallurgical characterization of W302 and W500 tool steels confirms standard material properties and proper heat treatment, eliminating these as failure causes. The finite element analysis (FEA) correlates simulated stress distributions (peaking at 925 MPa tensile and − 1037 MPa compressive) with observed crack initiation sites at some zones. The study demonstrates that machining defects and cyclic thermal loading significantly reduce die lifespan. By validating simulation results against physical die inspections, this work provides insights for optimizing die design, material selection, and machining processes to enhance durability and operational efficiency in hot forging applications.