2011 International Conference on Advanced Materials Engineering IPCSIT vol.15 (2011) (2011) IACSIT Press, Singapore An Investigation of Adhesion Wear Behavior of Tool Steel on Blanking Die Komgrit Lawanwong 1+, Natthasak Pornputsiri and Ghit Luangsopapun 2 1 Department of Tool&Die engineering, Faculty of Industrial and Technology, Rajamangala University of Technology Rattanakosin, Wang Klai Kang Wong Campus Prachubkirikhan 77110, THAILAND. 2 Thailand Institute of Scientific and Technological Research, Pathum Thani 12120, THAILAND. Abstract. This research work aims to exploration wear phenomenon on punch for blanking stainless steel. Three punch materials: JIS SKD11, and were studied. Those punches were hardened to fixed hardness 59 HRC. Stainless steel JIS SUS 430 having the same thickness of 2 mm were employed as workpiece material for the experiments. Clearance between punch and die of blanking tool was five percent of workpiece thickness. The strip was blanked into circular shapes of 25 mm. in diameter. Direct measurement of wear on blanking punch was carried out using optical microscope. Each punch was used for blanking 2,000 stroke/conditions. It was found that had shown lower wear than SK D 11 and respectively. The higher tungsten, molybdenum and vanadium content of increase the amount of carbide compound caused hard and durable of cutting edge. Beside, punch had shown highest adhesive because high chromium content has compatibility of elements. The compatibility of metal element caused of high adhesion, friction and wear rate. Punch material had shown high wear rate because of low chemical composition. Moreover punch had shown highest corrosion on cutting edge. Keywords: Adhesion wear, Blanking die, Stainless steel, Tool steel, Blanking Punch 1. Introduction One of important process in the metal forming is the blanking process. Blanking and piercing operations are widely used to cut sheet metal or plates by a shearing process between punch and die for mass production of precision engineering components. The quality of the parts, evaluated by the profile of the shaped surface depends on many factors such as tool design; punch material properties, stamping conditions and especially tool wear [1]. Tool wear in blanking process is very important in case of cutting high production. Hence the studies on tool wear have been able recently because the wear mechanism and contact conditions such as punch material conditions, surface roughness and generation of wear particles can not be explained. Many experimental researches have been done to investigate the wear phenomenon under the relatively simple tests [2 8] but the researches have been related to experimental observation of wear profiles on blanking tool could not explain wear phenomenon according to the increase of the number of pieces. Furthemore, the high precision of the parts, smooth sheared edges and high tool life, many research have been conducted. Takaishi [9] measured the wear contour on die and punch in the shearing process of stainless steel sheets according to various clearances between die and punch. Choy and Balendra [10] analyzed the wear phenomenon with describing the wear punch profile as the changes of radius around punch edge. Aoki [11] observed wear profiles on punch during sheet metal shearing process. Tronel and Chenot [12] predicted tool wear in hot forging process by the finite element method. In this paper focuses wear behaviors of the punch using three kinds punches materials are investigated. In addition, the behaviors of adhesive wear on blanking punch investigate by SEM and EDS analysis. + Corresponding Author Tel.: + 66 32 618570 fax: +66 32 618500. E-mail address: Komgrit.law@Kmutt.ac.th., Natthasak_idt@Hotmail.com, Ghit@Tistr.mail.go.th 25
2. Experimental Procedure The Stainless steel SUS 430 [JIS] is employed in the experiments. The chemical property of workpiece material was shown in table 1. Sheet strip of workpiece material thickness is 2 mm and 30 mm in width. A mechanical property of workpiece material was shown in table 2. The workpiece strip is shown in Fig. 1. The chemical properties of punch materials were illustrated in table 3. The blanking tool was designed to blank circular part of 25 mm diameter. The punch cutting edge insert and die button were made from JIS SKD11, and steel fixed hardened to 60 HRC [Fig.2]. The cutting edge was designed as an insert to the punch shank as shown in Fig. 3 in order to be easily removed [Fig.3]. Tool clearance employed in this experiment was 5% of sheet thickness [0.1 mm]. The photograph of blanking tool and die set is shown in Fig. 4. Air feeder installed with die set was used in the experiment. Experiments were carried out using a 60 tons mechanical press [Fig.5]. Blanking operations were performed without lubricant. 25 mm Fig. 1: Workpiece strip Fig. 2: Blanking punch Fig. 3: Shank of punch Fig. 4: Blanking die set with feeder Fig. 5: Mechanical press 60 tons In general, the degree of wear is higher for blanking punch than die. Therefore only blanking punch cutting edge is measured to quantity wear. The flank wear length and face wear length [Fig.6.] were measured under Optical microscope with program Axivo Version 5. Moreover, adhesive wear on blanking were observed by Scanning Electron Microscopy [SEM] and Energy Dispersive Spectrometry [EDS] analysis. Wear measurement have been made after 100, 200, 300, 500, 800, 1,000 and 2,000 strokes. Table 1: Chemical compositions of workpiece material.(%) C Si Fe 0.16 0.66 16.89 82.30 Table 2: Mechanical properties of workpiece material. Yield Strength Tensile Strength Elongation Hardness 289 N/mm 2 545 N/mm 2 27 % 142 HV 26
Table 3: Chemical compositions of punch materials (%) Material C Si Fe W Mn Ni Mo V 0.95 0.32 82.30 0.70 0.49 0.25 10.33 0.72 0.3 0.80 0.40 76.79 11.25 0.25 0.35 4.38 5.10 1.88 0.95 0.72 91.35 0.7 1.10 0.25 6.72-0.20 Face wear length Flank wear length Face wear position Flank wear position Fig. 6: Measurement on punch cutting edge 3. Results and Discussions 3.1. Influence of Particle Adhesion to Tool Wears In the blanking experiments the level of face wear length is lower than flank wear length because punch side slides back and forth against workpiece material during the blanking operation. Where as there is no sliding action between punch face and workpiece material. The results of flank wear length and face wear length of blanking punch with number of workpiece are shown in Fig.7 and 8, respectively. From Fig. 7 and 8 the wear length on punch has been investigated up to 2,000 strokes. It was found that the flank wear length quickly increases at the beginning of experiments up to 500 strokes. After 1,000 strokes, wear length becomes to stable. In Fig. 11, face wear length quickly increases at the beginning of experiment up to 500 strokes. After 500 strokes, wear length becomes to stable. 1.4 Flank wear length (mm) 1.2 1 0.8 0.6 0.4 0.2 Flank wear 0 0 500 1000 1500 2000 2500 Number of workpiece Fig. 7: The relationship of flank wears with number of parts. It was found that the flank and face wear length of punch material had shown lower wear rate than and respectively. The higher tungsten, molybdenum and vanadium content of increase the amount of carbide compound caused hard and durable of cutting edge. The flank and face wear length of punch material JIS; is larger than punch material JIS; and, respectively. Since punch material has low molybdenum and chromium composition that show low wear resistance. On the other hand punch material JIS; and JIS; had shown nearly wear resistance trend. Moreover JIS; had shown adhesion of workpiece to blanking punch more than punch material JIS; 27
. Further more,it was found that punch material JIS; high chromium similar workpiece [SUS 430] has compatibility of element. s 0.5 Face wear length (mm) 0.4 0.3 0.2 Flank wear 0.1 0 0 500 1000 1500 2000 2500 Number of workpiece Fig. 8: The relationship of face wears with number of parts. Adhesion phenomenal of workpiece material with cutting had shown Fig.9-11. Adhesion of workpiece on punch is large than punch and. It was found that compatibility between workpiece material [high chromium content] and punch material [ high chromium content] caused of adhesion on the surface. The compatibility of metal element caused of high adhesion, friction and wear rate. Adhesion of workpiece to blanking punch make sure the result of adhesion by EDS had shown in Fig.9. Adhesion of workpiece 100 Strokes Fig. 9: SEM image at 100X and EDS analysis of the adhesion on cutting edge of. 100 Strokes Fig. 10: SEM image at 100X and EDS analysis of the adhesion on cutting edge of. 28
100 Strokes Fig. 11: SEM image at 100X and EDS analysis of the adhesion on cutting edge of The results of SEM and EDS analysis from the experiments after 2000 strokes had shown in Fig.11- Fig.13. It was found that Fig.11-13 SEM image of surface cutting punch does not show adhesion of workpieces because junction of adhesion separated occurs at the interface. High pickup of workpiece on punch surface caused of high adhesion and high wear rate. EDS analysis had shown insignificant amount of adhesion on cutting edge. Furthermore, in the case of [Fig.11] had shown EDS analysis confirmed that there the high corrosion around surface. 2000 Strokes Fig. 12: SEM image at 100X and EDS analysis of the adhesion on cutting edge of. 2000 Strokes Fig. 13: SEM image at 100X and EDS analysis of the adhesion on cutting edge of. Corrosion 2000 Strokes Cl Fig. 14: SEM image at 100X and EDS analysis of the adhesion on cutting edge of SKD 3 29
4. Summary The aim of the study was explorations of adhesion wear on blanking die. Tool steel of higher tungsten, molybdenum and vanadium content had shown high wear resistance and durable of cutting edge. Moreover, punch high chromium content had shown compatibility of metal elements cased of high adhesion, friction and wear rate. Punch material had shown high wear rate and high corrosion because low chemical composition content. 5. Acknowledgements The authors would like to give our attitude to Department of Tools and Material King Mongkut s University of Technology Thonburi (Thailand) for supporting the die equipment and Office of the Higher Education Commission for funding of the research. 6. References [1] X.T. Zeng, S. Zhang, and T. Muramatsu. Comparison of three advanced hard coatings for stamping applications. Surface and Coatings Technology. 2000, 127: 38 42. [2] B. W. Rooks. The Effect of Die Temperature on Metal Flow and Die Wear During High Speed Hot Forging. Proceedings of the 15th MTDR Conference, Birmingham, England. 1974, 4: 447 495. [3] American Society for Metals, Failure Analysis and Prevention. Metals Handbook, 8th Edition, Vol. 10, ASM Handbook committee, ASM, Metals Park, OH, USA, 1974, pp. 134. [4] P. H. Hansen and P. H. Bay. A flexible computer based system for prediction of wear distribution in forming tools. Adv. Technol. 1990, Plasticity 1: 19 26. [5] M. J. Liou and H. S. Hasio. Prediction of die wear in high speed hot upset forging. ERC/NSDM Report, OSU. 1989, pp. 99-33. [6] J. P. Cescutti, N. Soyris, G. Surdon, and J. L. Chenot. Thermo-mechanical finite element calculation of three dimensional hot forging with remeshing. In: Proceedings of the Conference on Advanced Technology of Plasticity. Stuttgart, 1987, pp. 1051. [7] S. M. J. Ali, B. W. Rooks, and S. A. Tobias. The effect of dwell time on die wear in high speed hot forging. Proc. Inst. Mech. Eng. 1971, 185: 1171. [8] E. Doege, P. Groche, and T. Bobke. Application of adhesion theory to frictional and wear processes in hot die forging. Adv. Technol. 1990, Plasticity 1: 27 32. [9] K. Takaishi. Wear characteristics of the tools for perforating small holes in stainless steel stripes. J. Jpn. Soc. Technol. Plasticity 1988, 29 (330): 695 700. [10] C.M. Choy and R. Balendra. Simulation of the effect of tool geometry changes on blanking operations. In: Proceedings of the 9th International Cold Forging Congress, Solihull, UK. 1995, pp. 217 222. [11] I. Aoki. Tool wear in shearing of amorphous alloy foils: shearing of amorphous alloy foils II. J. Jpn. Soc. Technol. Plasticity 1986, 27 (308): 1078 1083. [12] Y. Tronel and J. L. Chenot. Prediction of tool wear using finite element software for the three-dimensional simulation of the hot-forging process. J. Mater. Proc. Tech. 1992, 31: 255 263. 30