Investigation of die wear by modelling the extrusion of Inconel 718

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http://eprints.org/relation/isVersionOf http://etheses.bham.ac.uk/id/document/34689 http://eprints.org/relation/isVolatileVersionOf http://etheses.bham.ac.uk/id/document/34689 http://eprints.org/relation/isIndexCodesVersionOf http://etheses.bham.ac.uk/id/document/34689 archive 4031 disk0/00/00/13/10 2014-03-03 13:17:32 2019-01-23 09:53:54 2014-03-03 13:17:32 thesis show 0 Lin Yu-Pei Lin Jianguo Dean Trevor University of Birmingham Investigation of die wear by modelling the extrusion of Inconel 718 unpub TN TS 10col_ephy Was embargoed until Dec 2013. Die wear is always an important issue in hot forming processes, such as in forging and extrusion. Die life affects the economics of process to product and in order to optimise die life, the mechanism of wear should be approached scientifically. The aim of this work is to provide a systematic method for predicting and quantifying wear occurring in the extrusion of INCONEL 718 (IN718), nickel superalloy. To characterise wear, the process prediction which contributes to it must be identified and quantified. First, material characterisation was carried out using the Gleeble physical materials simulator. Then a set of unified viscoplastic constitutive equations was developed suitable for modelling microstructural evolution of IN718, i.e. evolution of average grain size, dislocation density and recrystallisation under hot forming conditions, which enabled resulting flow stress to be calculated and the microstructure of formed parts to be predicted. Second, heat transfer and friction during the forming process were investigated, by upsetting cylinders and performing ring tests on IN718. The heat transfer experimental work centres rounded the development of a reliable method for the measurement of the sub-surface temperatures in the bottom die during upsetting. The experimental values of sub-surface temperatures under various lubrication and forging conditions were analysed. A theoretical approach was proposed for the determination of the values of effective heat transfer coefficient and effective friction factor, and comparisons of experimental results and those from FE simulations were made and satisfactory matchings were obtained. Finally, integration of the material model and derived boundary conditions using subroutines for FEA are presented. Qualitative studies of abrasive die wear carrying out in a FE package, DEFORM, on the effect of various hot forming cases are shown. The numerical results are compared with the observations from mechanical measurements and metallurgical examinations for the studied die. Good correlations are found for most cases, which prove the presented methods can be used effectively in the prediction of die wear. Also, further work is suggested to enhance the modelling capabilities. 2010-07 2009-09 graduation eng author checked This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder. Rolls-Royce public 192 University of Birmingham School of Engineering, Department of Mechanical Engineering d_ph na 2010-07 graduation