• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.88-93
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• 1998

The service life of tools in metal forming process is to a large extent limited by wear, fatigue fracture and plastic deformation. In warm forging processes wear is the predominant factor for operating lives of tools. To predict tool life by wear, Archard's wear model is generally applied. Usually hardness of die is considered to be a function of temperature in Archard's wear model. But hardness of die is a function of not only temperature but also operating time of die. To consider softening of die by repeated operations, it is necessary to express hardness of dies by a function of temperatures and operating time. By experiment of reheating of dies, die softening curves were obtained. Finally modified Archard's wear model in which hardness of die was expressed as a function of main tempering curve was proposed.

• Tribology and Lubricants
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• v.36 no.6
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• pp.320-323
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• 2020

Thin film coatings are commonly exploited to minimize wear and optimize the frictional behavior of various precision mechanical systems. The enhancement of thin film durability is directly related to the performance maximization of the system. Therefore, a fine approach to analyze the thin film wear behavior is required. Archard's equation is a representative and well-developed law that defines the wear coefficient, which is the probability of creating wear particles. A ploughing model is a commonly used model to determine the friction force during the abrasive contact. The equations demonstrate that the friction force and wear coefficient are inversely proportional to the hardness of the material. In this study, Archard's equation and ploughing models are modified with an effective hardness to minimize the gap between the experimental and numerical results. It is noted that the effective hardness is the hardness variation with respect to the penetration depth owing to the substrate effect. The nanoindentation method is utilized to characterize the effective hardness of Cu film. The wear coefficient value considering the effective hardness is more than three times higher than that without considering the effective hardness. The friction force predicted with the effective hardness agreed better with the results obtained directly from the friction force detecting sensor. This outcome is expected to improve the accuracy of friction and wear amount predictions.

• Tribology and Lubricants
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• v.39 no.3
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• pp.118-122
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• 2023

In our study, we develop a finite element model based on Archard's wear law to predict the cumulative wear and the evolution of the tool profile in friction stir welding (FSW) applications. Our model considers the rotational and translational behaviors of the tool, providing a comprehensive description of the wear process. We validate the accuracy of our model by comparing it against experimental results, examining both the predicted cumulative wear and the resulting changes to the tool profile caused by wear. We perform a detailed comparison between the predictions of the model and experimental data by manipulating non-dimensional coefficients comprising model parameters, such as element sizes and time increments. This comparison facilitates the identification of a specific non-dimensional coefficient condition that best replicates the experimentally observed cumulative wear. We also directly compare the worn tool profiles predicted by the model using this specific non-dimensional coefficient condition with the profiles obtained from wear experiments. Through this process, we identify the model settings that yield a tool wear profile closely aligning with the experimental results. Our research demonstrates that carefully selecting non-dimensional coefficients can significantly enhance the predictive accuracy of finite element models for tool wear in FSW processes. The results from our study hold potential implications for enhancing tool longevity and welding quality in industrial applications.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.3
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• pp.56-62
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• 2014

During the hot forging process, the most common cause of tool failure is wear. Tool wear results in the gradual loss of part tolerances, after which eventually the tool must be replaced or repaired. In order to maximize the lifetimes of forging tools, it is important to investigate the wear mechanisms of these tools. In this study, the hot forging of the outer race of an automotive constant-velocity joint was analyzed by a finite element method to investigate the wear distribution, especially the amount and location of the maximum expected wear damage, using Archard's wear model, which was modified considering the forging temperature. Forging analyses were carried out after modifying blocker forging tools based on established versions. The modified blocker tools resulted in an increase in the tool life up to 31% with a finisher punch.

• Tribology and Lubricants
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• v.36 no.5
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• pp.262-266
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• 2020

Herein, we present a numerical investigation of wear analysis of sliding systems with a constant speed subjected to Archard's wear law. For this investigation, we compared two methods: eigen-wear analysis and adaptive meshing technique. The eigen-wear analysis is advantageous to predict the evolution of contact pressure due to wear using the initial contact pressure and contact stiffness. The adaptive meshing technique in finite element analysis is employed to obtain transient wear behavior, which needs significant computational resources. From the eigen-wear analysis, we can determine the appropriate element size required for finite element analysis and the time increment required for wear evolution by a dimensionless variable above a certain value. Since the prediction of wear depends on the maximum contact pressure, the finite element model should have a reasonable representation of the maximum contact pressure. The maximum contact pressure and wear amount according to this dimensionless variable shows that the number of fine meshes in the contact area contributes more to the accuracy of the wear analysis, and the time increment is less sensitive when the number of contact nodes is significantly larger. The results derived from a two-dimensional wear model can be applied to a three-dimensional wear model.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.4
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• pp.47-54
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• 2013

The main cause of die failure in hot forging is wear. Die wear directly generates the gradual loss of part tolerances, thereby causing deterioration in the dimensional accuracy of a forged part. It is very important to estimate forging cycles, called as die life, at which the die should be repaired or replaced. In this study, in order to estimate the hot forging die life, the finite element simulation of wear on an asymmetric part like a ball joint socket used in vehicle was carried out based on Archard's model. Finite element simulation results were compared with wear amounts of a used die that were measured using a contact stylus profilometer. The simulation results were in relatively good agreement with measurements obtained from the virtual die which was used by 7,000 forging cycles in a forging industry. Consequently, the die life in the hot forging of the ball joint socket was estimated by 10,500 forging cycles on the finisher die.

• Transactions of Materials Processing
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• v.7 no.3
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• pp.274-281
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• 1998

The service life of tools in metal forming process is to a large extent limited by wear, fatigue fracture and plastic deformation. In elevated temperature forming processes wear is the predominant factor for tool operating life. To predict tool life by wear Achard's model is generally applied. Usually hardness of die is considered to be a function of temperature. But hardness of die is a function of not only tem-perature but also operating time of die. To consider softening of die by repeated operation it is necessary to express hardness of die by a function of a function of temperature and time. By experiment of reheating of die softening curve was obtained and applied to suggest modified Archard's Model in which hardness is a function of main tempering curve.

• Tribology and Lubricants
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• v.16 no.5
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• pp.357-364
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• 2000

In this study, the sliding wear in spur gears, using Archard's wear model, is analyzed. Formulas of tooth sliding wear depth along the line of action are derived. The tooth profile is modified Id make a smooth transmission of the normal loads and the cylinder profile for reducing the pressure spike is suggested. The sliding wear rate is calculated with these profiling results. We expect these modification methods to contribute to the reduction of sliding wear not only in the root, but the tip of tooth and tooth edge.

• Tribology and Lubricants
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• v.33 no.3
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• pp.98-105
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• 2017

A pin-on-disk test is performed to measure the wear volume of a ductile cast iron (DCI) roll when it wears down using a high carbon steel and two alloy steels at different sliding velocities between the roll and the material (steel). Normal pressure is set as constant and test temperatures are 400, 500 and $600^{\circ}C$. In addition, thermal softening behavior of the DCI roll is examined using a high-temperature micro-hardness tester and the surface hardness variation of the DCI roll is expressed in terms of temperature and heating time. Based on experimental data, a wear coefficient used in Archard's wear model for each material is obtained. The wear volume is clearly observed when the test temperature is $400^{\circ}C$ and sliding velocity varies. However, it is not measured at temperatures of $500^{\circ}C$ and $600^{\circ}C$ even with variations in sliding velocity. From the optical photographs of the pin and disk, the abrasive wear is observed at $400^{\circ}C$ clearly, but no at $500^{\circ}C$ and $600^{\circ}C$. At higher temperatures, the pin surface is not smooth and has many tiny caves distributed on it. It is found that wear volume is dependent on the carbon contents rather than alloy contents. Results also reveal that the variations of wear coefficients are almost linearly proportional to the carbon contents of the material.

• Transactions of Materials Processing
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• v.16 no.6
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• pp.479-487
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• 2007

Die life is generally estimated taking failure life and wear amount into consideration. In this study, the forging die life was investigated considering both of these two factors. The fatigue life prediction for the die was performed using the stress-life method, i.e. Goodman's and Gerber's equations. The Archard's wear model was used in the wear life simulation. These die life prediction techniques were applied to the die used in the forging process of the socket ball joint of a transportation system. A rigid-plastic finite element analysis for the die forging process of the socket ball was carried out and also the elastic stress analysis for the die set was performed in order to get basic data for the die fatigue life prediction. The wear volume of the die was measured using a 3-dimensional measurement apparatus. The simulation results were relatively in good agreement with the experimental measurements.