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
THAI TRIBOLOGY ASSOCIATION (TTA)
Numpon Mahayotsanun
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Fuel Economy Safety Surface Quality Energy (Reduced Friction) Low Density and High Strength Superior Surface Finish
Superior Surface Finish Low Density and High Strength
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Energy (Reduced Friction)
Increased Load/Stress Increased Die Damage (Wear) Short Die Life
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Rolling Stamping Punching Forging
Source: (1) www.custompartnet.com, (2) www.whtildesley.com
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Rolling Stamping Punching Forging
Source: www.sciencedirect.com
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Related Die Properties
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.
Damage Sheet Forming Process
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Related Die Properties
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.
Damage Hot Forging Process
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Source: Mang T, Bobzin K, Bartels T. Industrial Tribology: Tribosystems, Wear and Surface Engineering, Lubrication. John Wiley & Sons; 2011.
Counter body Base body v FN
“Tribo” = “Rubbing” Interacting Surfaces Multidisciplinary
Energy Waste Reduction Service Life Extension Savings
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Die Workpiece
v
FN Lube
Key Considerations Die (Material and Coating) Workpiece (Material Properties) Lubrication (Lubricant Properties) Condition (Pressure, Temperature, Velocity, etc.)
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Countermeasure Plan Step I - Die Life Criterion Defjnition Step II - Die Damage Observation Step III - Die Damage Causes Step IV - Die Damage Causes Solving Step V - Countermeasure Plan Step VI - Die Damage Causes Check
Inferior Apperance Deterioration of Accuracy Deveation from Accuracy Standard Surface Roughening Plastic Deformation Wear Breakage Adhesive Wear Abrasive Wear Fatigue Overload Fatigue Wear Adhesion Excessive Thermal Load Large Alternating Stress Severe Forming Conditions Higher Strength Tool Materials Higher Toughness Tool Materials Improvement of Lubrication Surface Hardening Surface Treatment Adhesive Strength Hardness of Coating Film Strengthening of Base Material Compatibility with Toughness Deterioration of Strength Many Surface Defects Change in Shape
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.
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Source: www.thefabricator.com
50,000 Parts 1,200,000 Parts
Coating
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Source: Ian Taylor and Prof. Robert Wood, The Scale of Tribology and Associated Cost Savings
Faster (High speed -> increased production) Harder (Ability to cut or form harder materials) Cheaper (Less lubricants -> materials saving) Longer (Extended tool life -> fewer replacements) A 20% reduction in manufacturing time gives 15% saving per part. This is due to a less time on machinery and staffjng. If a company produces the same quan- 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- timized solution.
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Increased Toughness
Die Base Material Die Coating Workpiece Lubricant
Material Properties (Heat Treatment) Increased Strength Surface Engineering (Coating & Texturing) Reduced Friction & Heat Lubricants Selection (Type & Viscosity) Optimized Condition Process Parameters Adjustment
Operating Condition
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Tribology Knowledge (Friction, Wear, Lubrication) Material Properties (Heat Treatment) Tribology Testing (Tribometers) Surface Engineering (Coating & Texturing) Die Wear/Life Prediction (Theories, FEA) Lubricants Selection (Type & Viscosity) Selection (Material, Lubricant, Coating) Process Parameters Adjustment Design (Die, Process)
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Tribology Knowledge (Friction, Wear, Lubrication) Tribology Testing (Tribometers) Die Wear/Life Prediction (Theories, FEA) Selection (Material, Lubricant, Coating) Design (Die, Process)
Research & Development Tribology Training Networking
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Research & Development Tribology Training Networking
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
www.tta.or.th
THAI TRIBOLOGY ASSOCIATION (TTA)