Dworzak Łukasz, Hawryluk Marek, Janik Marta
Department of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, Poland.
Mahle Poland, Mahle 6, 63-700 Krotoszyn, Poland.
Materials (Basel). 2021 Jan 4;14(1):212. doi: 10.3390/ma14010212.
The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings that ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM (Scanning Electron Microscope). For the best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool up to the maximum service life.
本文介绍了润滑和冷却系统参数设置（电磁阀开启时间以及润滑剂供给压力与其用量的关系）对高镍钢阀门锻造首次锻造操作中所用模具磨损影响的研究结果，目的是选择最佳润滑条件，从而减少模具磨损。基于对工业生产过程中润滑情况的观察发现，很大一部分润滑剂未能到达模具型腔，而是到达了型腔外部，这会导致模具磨损，原因是锻造材料粘附在工具表面导致咬死，同时还会造成润滑剂消耗量大以及压力室中有污垢。作者提出了自己的移动式润滑和冷却系统，与目前工业生产过程中使用的固定润滑系统不同，该系统可进行广泛的调节，并具备整个系统的自动清洁程序。首先，在实验室条件下进行测试，以确定最高润湿性以及留在工具型腔内的润滑剂。这些测试确定了润滑系统参数设置，确保在无锻造过程的情况下，最大量的润滑剂留在冷模具型腔内。然后，为验证所得结果，在阀锻件热模锻的工业生产过程中进行了测试，生产批量为短至500件锻件。将结果与基于3D扫描和使用扫描电子显微镜（SEM）进行的表面形貌分析对工具和锻件几何形状变化的测量结果进行了比较。对于最佳结果（润滑剂剂量和作用时间的设置变体），使用新工具进行锻造过程直至达到最大使用寿命。
