An investigation into the current and future methods of manufacture and repair of tools and dies for the metals forging industry

摘要

The forging of metals, although one of the oldest metals processing procedures, has a unique role to play in the provision of intermediate and semi-finished products for all industrial sectors. The forging process is capable of manufacturing near net shape components, exhibiting enhanced mechanical properties, and produce less waste material than alternative production methods. The cost effectiveness of the forging process, particularly in high volume applications, is significantly influenced by the cost of tool and die manufacture and maintenance. Therefore techniques to extend die life and to repair worn dies are of great importance to the forging industry. This paper looks at the various forging processes, and the associated wear mechanisms that these processes produce. It looks at steel and nickel base die materials, relating these to the materials to be forged and forging temperatures. Current die materials and repair techniques are also evaluated. More contemporary techniques such as laser and electron beam welding are introduced, along with laser deposition systems. The practical application of CAD CAM techniques for tool design is discussed as is the use of FEM computer based simulation for assessment of die wear and subsequent choice of functionally graded materials for high wear areas. The application of these processes to rapid prototyping of forging dies is also discussed.