SIMTech Technical Report (PT/02/037/FT)

Pre-stressing of Forging Die to Improve

Tool Life

Goh Chwee Sim

Dr Choy Chee Mun

(Forming Technology Group, 2002)

Pre-stressing of Forging Die to Improve Tool Life
1 BACKGROUND
Tool life represents the number of forming
operations which can be processed by a
single set of tools (or tooling system)
simultaneously ensuring the required
product quality. Continuous improvement
in tool life is required due to increasing
challenges in producing net and near net
shape components, as well as the
processing of new materials, and
components with higher complexity [1].
To date, most of the finite element
analyses aim at improving tool life through
direct simulations, where the user defines
a complete set of input data, including
discretised geometry and movements of
the tool system, material constants and
tribological parameters [2]. Direct
analyses can provide valuable information
about the forming force and energy
consumption, as well as insight into
material flow and distributions of stress,
strain and temperature fields during
forming [1]. Pre-stressing of tooling has
been proven to lengthen tool life [3],
however, less information is available on
the effect of pre-stressing on tool life using
finite element analysis. It is believed that
simulation drastically shortens the tedious
trial and error process of modifying the
pre-stress values to lengthen the tool life.
In this paper, the pre-stressing effect on
tool life is evaluated using
ANSYS®/LSDYNA finite element
software. A comparison is made on the
pre-stressed and normal dies to determine
the stress distribution and displacement of
the die during forging.
2 OBJECTIVE
To determine the effect of pre-stress on
tool life improvement.
3 METHODOLOGY
The two-dimensional axis-symmetric
model which consists of a die, die ring,
Keywords: Pre-stress; Tool life; Finite element analysis; Extrusion
PT/02/037/FT
punch, die support and billet are simulated
as plastic bodies (MAT_POWER_LAW_
PLASTICITY). The material constants of
the tool steel (die, die ring, punch and die
support) and low carbon steel (billet) used
in this simulation are presented in Table 1.
Auto-remeshing was activated to prevent
excessive damage to the deformed
elements. Stress in the X – radial (σx), Y –
axial (σy) and Z – circumferential (σz)
directions, together with the hydrostatic
pressure [1/3(σx + σy + σz)] in the die
geometry are evaluated.
Figure 1 shows the configuration of the die
set-up. Pre-stressing of the die and die
ring are required to prolong the tool life
and to prevent premature tool failure.
Compressive stresses are applied along
the negative x-direction on the die and die
ring using the displacement of a rigid body
(MAT_RIGID). The displacement of the
rigid body A is calculated to be 0.4/100 of
the diameter of the die, which corresponds
to the actual displacement of the die
during production. These compressive
stresses are applied to counteract the
tensile hoop stresses produced in the die
during forming of the billet. Upward
compressive stresses are also applied
through the movement of the rigid body B
along the positive y-direction to close any
gaps between the dies. This closure is
required to prevent squeezing of the billet
material into the gap between the dies to
form flashes during forging.
A comparison of the pre-stressed and
normal dies was evaluated to identify the
stress distribution and displacement of the
die during forging. This comparison
allowed the beneficial effect of pre-
stressing on tool life to be efficiently
revealed.
A DEC/ ALPHA 600 series 64 bit
workstation with an OSF1 version 4.0
operating system installed with ANSYS
version 5.6 was used for the pre-
processing. PC-Dyna version 960 was
used as the FE solver and post-processor.
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Pre-stressing of Forging Die to Improve Tool Life PT/02/037/FT

Material Properties of Tool Steel and Low Carbon Steel Used in the Die and Billet
n
Material Material Properties based on σ = Kεε
Density/ Young’s Poisson’s Strength Hardening
3
Kg/mm Modulus/ Ratio Coefficient, K / Exponent,
MPa MPa n
-8 6
Tool Steel 0.785x10 0.210x10 0.3 5645 0.148
-8 6
Low Carbon Steel 0.785x10 0.210x10 0.3 530 0.26

Punch
Displacement in y
direction = -45mm

Billet
Deformation Behaviour
represented by σ = Kεn

Rigid Body A

Die

Die Support
y
z
x
Rigid Body B

Figure 1 Configuration of the Die Set Up

4 RESULTS AND DISCUSSIONS compressive hoop stress on the inner die

rings and most importantly, the die [3].
4.1 Effect of Pre-Stress on the
Stress Distribution in the Die
Figure 2 shows the effect of pre-stressing
on the stress distribution in the die
During extrusion, punch pressure exerted
geometry. It can be seen from Figure 2a
on the billet will result in a radial
that displacement of the rigid body A by
compressive force acting on the bore of
0.4/100 of the diameter of the die leads to
the die causing it to expand. This radial
a compressive hoop stress of about 800
compressive force causes tensile hoop
MPa in the die. This stress value
stress in the die which is too great for the
corresponds to a simple theoretical
die to withstand without external support.
analysis based on σ = Eε, and this result
Hence, it is a common practice to build up
obtained quantifies the reliability of using
the die from a number of rings. Therefore,
this simulation tool. The displacement of
the die set-up will consist of a die and one
rigid body B to obtain a stress value of
or more die rings. The die rings are
1200 MPa (Figure 2b) is based on trial
designed such that there are interference
and error. FE results suggested that an
between mating surfaces of adjacent
upward displacement of 0.3 mm is needed
rings, and also between the inner die ring
to eliminate this trial and error process.
and the die. This interference imposes a

2
 Pre-stressing of Forging Die to Improve Tool Life
X Pre-Stress
Die Wall under
Compressive
Pressure
Y
Upward
Stress
(a)
Y
Upward
Stress
(b)
Figure 2 Effect of (a) X Pre-Stress and (b) Y
Upward Stress on the Stress Distribution in the
Current Die Configuration
Figure 3 shows the final pressure
distribution in the die geometry, with the
billet being extruded to the final shape,
with pre-stressing in the x direction and
upward stress applied in the y direction.
The hydrostatic pressure and various
stresses in the x, y and z directions
respectively along the die wall (arrow)
under different pre-stress states are
presented in Table 2 to give a more
detailed analysis of the results.
PT/02/037/FT
X Pre-Stress
Figure 3 Final Pressure Distribution in the
Current Die Geometry
It can be seen from Table 2 that, when
pre-stress has been applied to the die,
together with upward stress in the y
direction, as in the current die geometry,
the die will be under a compressive state
throughout the whole forging operation.
The vital stress that can cause the die to
fracture, the hoop stress (σz), has a high
compressive value (-833 MPa), and this is
beneficial to the tool life of the die,
because any tensile hoop stress
developed during forging can be
counteracted. The presence of this high
compressive stress is the result of the
application of the pre-stress in the x
direction.
When upward stress in the y direction is
applied, but pre-stress in the x direction is
removed (with rigid body A kept in place),
as shown in Table 2, it is found that the
die wall is still in a compressive stress
state. This raises some ambiguity to the
accuracy of the results, because when no
pre-stress is applied in the x direction to
counteract the tensile hoop stresses
developed during forging, the die should
be in a tensile state, when radial
compressive forces from the punch acts
on it. However, when the initial stress in
the die is examined, before the punch
moves down, it is found that the stress
state is also compressive (Table 3).
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Pre-stressing of Forging Die to Improve Tool Life PT/02/037/FT

Table 2 Pressure and Stresses in the X, Y and Z Directions Respectively Along the Die Wall Under
Different Pre-Stress States
Die Hydrostatic σx** σy σz
Pressure* (Radial) (Vertical) (Hoop)
With X Pre-Stress & Y Upward Stress 394.3 -102.2 -247.3 -833.0
With Y Upward Stress, but no X Pre- 113.1 -49.4 -214.4 -75.5
Stress
No X Pre-Stress and Y Upward Stress -40.0 -14.7 47.4 108.3

*Hydrostatic Pressure in MPa: positive (compressive), negative (tensile)

**σx, σy & σz in MPa: positive (tensile), negative (compressive)

These compressive stresses are found to
be caused by the upward stress applied in
the y direction before forging. This upward
stress causes the die to be in the
compressive stress state before the
forging operation, and during forging,
tensile hoop stresses developed are
compensated by the compressive hoop
stresses already existing in the die. And
because the compressive hoop stresses
caused by the y upward stresses are
much lower than those produced by the x
direction pre-stressing, the resultant
compressive hoop stresses in the die are
also much lower (-75.5 MPa).
To confirm the above observation, the
upward stress is also removed, together
with the pre-stress in the x direction (with
rigid body A kept in place). In this case,
the die will have no stresses before the
punch moves down (Table 3). During
forging, it is found that the hoop stresses
in the die are in the tensile state (Figure
4). This observation confirms the earlier
belief that the die should be in a tensile
stress state during forging without pre-
stress application. These tensile hoop
stresses are very detrimental and will
cause the die to fracture after some
forging cycles.
that the die is moving towards the punch,
and this is otherwise for the positive value.
It can be seen from Table 4 that when no
pre-stress or y upward stresses are
applied to the die, the die actually moves
backward (or expand) during forging due
to the hoop stresses in the die caused by
the radial forces of the punch. This
deflection is accentuated without the
support of the rigid body A. The expansion
of the die caused by the hoop stresses will
result in cracks formation and failure of the
die after many forging cycles. When pre-
stress or y upward stresses are applied,
shrinkage of the bore of die occurs before
the punch moves down, and this
shrinkage is used to compensate for the
expansion of the die during forging. These
deflection results obtained further support
the application of a pre-stress to lengthen
the life of the forging tools.
Die Wall under
Tensile Hoop
Stress

4.2 Effect of Pre-Stress on the

Elastic Deflection of the Die

Table 4 shows the percentage deflection

of the die relative to its initial (no stress)
configuration after pre-stressing, and
when the punch has moved down
completely. A negative value indicates
Fig 4 Die Wall Under Tensile Hoop Stress
When No X Pre-Stress or Y Upward Stress is
Imposed

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Pre-stressing of Forging Die to Improve Tool Life PT/02/037/FT

Table 3 Initial Stress State in the Die Under Different Pre-Stress States
Die Hydrostatic σx σy σz
Pressure* (Radial) (Vertical) (Hoop)
With X Pre-Stress & Y Upward Stress 487.3 -112.6 -412.9 -936.6
With Y Upward Stress, but no X Pre-Stress 203.8 -27.1 -302.6 -281.7
No X Pre-Stress and Y Upward Stress 0 0 0 0

Table 4 Percentage Displacement of the Die Relative to its Initial (No Stress) Configuration After Pre-
Stressing and When the Punch has Moved Down Completely
X Pre- Y Upward Rigid Body % Deflection % Deflection After Punch
Stress Stress A After Pre-Stress Moves Down
Yes Yes Yes -0.39 -0.35
No Yes Yes -0.13 -0.08
No No Yes - 0.04
No No No - 0.07

5 CONCLUSIONS REFERENCES

1. Pre-stressing imposes a [1] Tool Life & Tool Quality in Cold Forging,
compressive hoop stress in the
die, which can compensate the
detrimental tensile hoop stress
developed during forging.
2. Expansion of the die during forging
is prevented by application of a
pre-stress.
3. Reduction of both tensile hoop
stress and expansion of the die
during forging can result in longer
life of the die.
6 INDUSTRIAL SIGNIFICANCE
Part 1: General Aspects of Tool Life, ICFG
Document No. 14/02, Meisenback Verlag
Bamberg (1994)
[2] Huetink & Baaijens (eds), NUMIFORM
1998:Proceedings of the Sixth
International Conference on Numerical
Methods in Industrial Forming Processes,
Simulation of Materials Processing:
Theory, Methods and Applications,
Balkema (1998)
[3] R.A.P. Morgan & O.B.E., M.I. Mech.E,
Toolings for Cold Extrusion, Conference
on Cold Extrusion of Steel, Institute of
Sheet Metal Engineering

Reinforcement pre-stressing has been an

established method for lengthening the life
of forging tools. However, the use of finite
element analysis to determine the amount
of pre-stress required is still relatively
unexplored. Simulation not only saves
time by eliminating the conventional trial
and error method of determining the
amount of pre-stress required, it also
reduces production costs by preventing
premature failure through optimizing the
die conditions.