15. - 17. 5.

2013, Brno, Czech Republic, EU

INVESTIGATION OF DEFECTS IN FORGING TOOLS BY NONDESTRUCTIVE DETECTION

METHOD

Dana STANČEKOVÁ, Andrej CZÁN, Michal DERBAS

University of Zilina, Zilina, Slovak Republic, EU

[email protected], [email protected], [email protected]

Abstract
The use of forging tools in mass production has led to an enormous increase in the consumption
of forging tools and the need for rapid and flexible tool renovations. A major lack in the renovations is to
identify cracks propagating from the surface towards the core of the basic components. This article deals
with the application of nondestructive detection technology when considering the size of die forging defects
that arise in the process of forming.
Keywords: forging tools, renovation, nondestructive detection technology

1. INTRODUCTION
Forging is one of the most economical manufacturing methods for making parts out of steel and non-ferrous
metals. Advantages of forging in comparison to other methods include significant savings in materials, higher
production rate, better grain structure and better surface quality. Requirements for construction materials for
forging tools must comply with the high demands of the mechanical, physical and chemical aspects of high
strength, toughness and hardness. Technical and technological processes depend on these characteristics,
which directly affects the cost of the individual components and their competitiveness. Following impact, the
tools have a longer shelf life, thus there is less downtime needed for replacement and repair. In this way, we
can make better use of production machinery and equipment. Tools made of special hardened materials are
highly cost-intensive, and therefore their design already considers the possibility of manufacture, renovation
or repair. Generally when machining materials with impaired machinability and high hardness, non-cutting
technologies that achieve high productivity, flexibility and excellent functional properties are used. The
biggest problem is to choose the right technology, which will restore the original mechanical and physical
properties of tools or instruments as soon as possible at a competitive price.
Temperature fluctuations on the surfaces of forging tools, plastic deformation, and the influence of thermo-
mechanical stress lead to alternating thermal fatigue and cause surface cracks. These defects significantly
affect the quality of finished forgings and the lifespan of the forging die itself. To capture and track these
defects, several destructive and nondestructive methods can be used for the detection of cracks within the
tools. For fixing forging dies, nondestructive methods that do not disturb the shape and surface components
are desireable.

2. DIE FORGING
Die forging is used for mass production (Fig. 1). The principle
is that the heated material takes the final shape of the die
cavity with one or more stroke. This method gives a more
accurate shape compared to free forging. The accuracy of the
Fig.1. The principle of die forging
surface can be significantly improved by further finishing
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operations such as calibration and a quality surface can be achieved, which should not be further cultivated.
Using die forging, a high degree of reduction of material and fibres is achieved, which has a positive effect
on the mechanical properties of the material [1].
To start, a blank is inserted into the lower part of the opened die. By action energy shaping, the machine
moves one part of the die against another while the starting material fills the cavity. By fully grasping the die
cavity, it is filled and transformed into the desired shape. The procedure for filling a cavity influences the
speed of deformation, which depends on the type of machine. The impact of hammers causes greater speed
creep in the direction of shock and the force of the press still makes better filling of cavities in a direction
perpendicular to the acting force. These differences in filling the die cavity influence the choice of the type
of molding machines and forging operations for the part [2].

3. CURRENT STATUS OF SOLVED ISSUE

Blacksmith tools manufactured from special tool steel tool are highly cost intensive. The main part of the cost
is attributable to the material itself, heat treatment and other chemical-thermal treatment of the surface.
Therefore, the possibility of renovation or repair is already considered in the actual design of the die
structure. An important aspect of the renovation process itself is the right choice of technology to restore the
power tool’s original mechanical and physical properties, of course at a competitive price. The main
challenge in selecting appropriate technology for tool renovation is heat treatment of high hardness and die
surface treated by nitrided layer, which increases the resistance of the die cavity to scratching. In particular,
the forging process leads to mechanical stresses that cause wear on the shape of the die (Fig. 2) and also
fatigue fracture, which reduces the quality of finished forgings. Therefore, after a fixed life, a die forging is
removed from the forging process and sent for repair or renovation.

Fig. 2. Wear of die forging Fig. 3. Surface fatigue cracks on the

functional surface of die

3.1. Cracks and their flow

Cracks can occur as a result of using the wrong terms of production. A poor cooling process for cast or
forged parts, overheating during the grinding, or excessive tension during the manufacturing process are
common causes of cracks. Cracks are defined as a narrow gap where the length along the surface is at least
ten times greater than the depth in the material, and a visual example of cracks on a forging tool is shown in
Fig. 3. In addition, the width of the fracture is very small, at least ten times smaller than the depth. The
bottom of the fracture is mostly sharp, causing sharp notches in the material. Due to mechanical stress,
especially when changing or alternating loads, there is a sharp notch at the bottom of the tension that can
cause enlargement of cracks [3].
It is therefore very important to always pay close attention to cracks. Early detection and assessment of
cracks are very important. This is especially true for surface cracks. In most cases exposed parts such as
auto parts are subjected to the biggest stress on the surface. It is also important to note that not every flaw
can damage components. The rule of crack mechanics says that some cracks can be tolerated. This
depends on many factors and sometimes it is difficult to decide whether to use standard methods of
nondestructive material testing [3].
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3.2. Renovation of die forging

Renovating is a special case of repair, where the repaired object is a machine component. It is a work of
restoring their functional properties to damaged machine parts. Renovation is a set of activities carried out in
order to restore the operational status of components and extend their lifespan. It is a reparation in which
worn parts are restored to their original geometric shape, size, and functional and mechanical properties in
accordance with drawings and technical specifications. Renovation may be seen as a repair sub-sector,
which contributes to reducing the cost of restoration and operation of machinery, but it can also be seen as a
special case of recycling materials, which, moreover, reduces the demand for raw materials and energy
sources [4].
Before renovation, it is necessary to map the extent of tool wear and infer the extent of renovations and
technology needed. Range is determined by the size of the fracture surface that is removed by machining
such that the outer surfaces show no signs of defects. This process is usually performed by visual
observation using surface optical devices that can find the largest size defects generated in the forging
process, which prevent efficient use. As control is exercised by subjective workers who often cannot assess
the degree of wear, not least the size of the fracture, the process is repeated until all defects are removed. It
often happens that the extent of wear is destructive for the die, which is able to detect only a few controls
and subsequent surface treatment. From an economic point of view, the time and cost to renovate increases.
Sometimes it is necessary to completely remove the forging dies during the renovation process due to
excessive wear and damage. This process is well run and used in practice and seeks to simplify and
intensify the technology of renovations.

Fig. 4. Examination of cracks by nondestructive technology

For this purpose, various methods are used to survey defects in materials and products, whether they are
destructive or nondestructive detection technologies that can assess the extent of wear and thus offer more
renovation options. Defectoscopy is a nondestructive method, and it is one of the best choices for renovation
due to its ability to change the status of the sample for future use (Fig. 4).

4. MAPPING OF CRACKS BY ULTRASONIC DEFECTOSCOPY

Ultrasonic testing arose from the need to identify hidden internal defects in components that could lead to
accidents involving finished products. It is a nondestructive testing method and has considerable importance
in improving quality and reliability in industry, especially in engineering. It is one of the most important
methods of nondestructive testing of materials and can detect material discontinuities resulting from the
production process well as from mechanical stress during operation [5].
The effect of defects on the strength of the material depends on its nature, size and shape, which determine
the nature of spatial defects. Planar defects include cracks, cold joints, unattaching and duality, while spatial
character defects include bubbles, cavities and pores and are usually less dangerous for the strength of the
material. Outside of these defects, whose nature is to be determined, there is also a transition formed
between major groups, such as rows of pores and hair pores. The option to specify the nature of the defect
depends on the shape of the object and the presence of a surface to which it is possible to attach the
appropriate type of ultrasound probe. Detection of the nature or orientation of the defect is based on the
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directivity of ultrasonic transmission. The reflective property of these components, and thus the shape of the
echo, depends on the nature and size of the defect [6].

4.1. Methods for ultrasonic flaw detection

Ultrasonic DiO - 562

The defectoscopic machine STARMANS ULTRASONIC FLAW DETEKTOR DiO - 562 - reflective device is
used for the detection of defects in the tested material and is equipped with a universal probe for measuring
flat surfaces.
Samples 1
1
2
2
3
3

Fig. 5. Measurement of dies: 1 - measured die, Fig. 6. Measurement of dies: 1 - front die,
2 - measured crack, 3 - ultrasonic probe 2 - measured crack on volume, 3 - measurement
from the bottom of the die
Measuring systems use three methods: measuring probes, die-limited options, and cavity shape
measurement (Fig.5). Crack measurements can be from three directions, namely from the face, the outer
periphery, and the bottom of the die (Fig. 6, 7). The basic measurement is focused on the forging die head
(Fig. 8), but this does not give the desired results, because in this way it is not possible to capture the crack.
This is justification for the diversity of internal die profile and a type of probe that has not been adapted for
this measurement procedure.

Fig. 7. The principle of crack depth Fig. 8. Start measuring the forehead and around the
detection by ultrasonic method perimeter dies

Fig. 9. Dies of two different internal profiles

As a result, measurement is focused on the method of measuring the outer perimeter of the die. The die
profile with rounded internal diameter by producing turning (Fig. 9, left), and it is not possible to measure the
outer circumference or any significant and relevant dimension of the crack. Only cracks with forged internal
profile produced by milling can be detected, as shown in Fig. 9 on the right. Detail of cracks and record
measurements are shown in Figs. 10 and 11.
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Fig. 10. Detail of cracks of examined die 1.1 Fig. 11. Recording of failure and end echo for 2 cracks

Ultrasonic flaw detection apparatus EPOCH LT a EPOCH 600

On the sample, there were several cracks that could be visually detected and the intention was to measure
their size using this device. Unfortunately, even this method has not conclusively determined whether there
was a crack or whether there is an error. This is one of the main reasons we consider the complex and
rugged profile of the crack, which caused consistent contact with the surface probes of die. For this reason,
and following dialogue, it was decided to repeat the measurement with the device EPOCH 600th. This
device unfortunately yielded equally unreliable results as its predecessor ECPOH LT and measurement has
been completed.

5. EXPERIMENTAL MEASUREMENTS USING A DEVICE RMG 4015

 The crack depth measurement device RMG 4015 was used to detect the depth of the cracks.

 Die 1 performs a die forging with recesses of a cylindrical inner cavity.

Fig. 12. Detail of cracks 3, 4 and 5 on die 1 Fig. 13. Course of 3. and 4. Crack in die 1

Fig. 14. Detail 7. and 8. Crack on die 1 Fig. 15. Course of 7. and 8. Crack in die 1
As seen in the graph of 7. cracks (Figs. 14, 15), the crack spreads from the internal functional area across
the top blacksmith dies up to the edge. From the measured values of the crack depth can be read that the
maximum depth of the crack is located at the edge of the die. The course of the cracks is significantly
different from the other measured cracks, which are much shorter and are found mainly in the vicinity of the
internal curvature of the die cavity. This crack has a particular risk, because the next time the die is used
there could be further spread and deepening of the cracks, which could lead to the exclusion of the forging
die and inability to carry out further renovations.
In 7. crack the top five crack depth measurements were carried out at the top of the forging die, therefore the
depth of measurement has the value 0. The measurement was carried out towards the edge of the external
die to the die cavity inner edge.
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Fig. 16. Graphical representation of cracks in die 1

From the graphic course (Fig. 16) it can be seen that the crack depth increases to a maximum and then
begins to fall. It is also possible to see that on the die there are cracks of different depths. Measuring cracks
using the RMG 4015 device was quick and smooth, making it possible to demonstrate the practical use of
the machine in engineering practice.

6. CONCLUSION
In order to increase knowledge about the use of technology for nondestructive examination of cracks and
consult with private companies that have long experience in the investigation of material defects, the
potentiometric method was used. Equipment RMG 4015 proved reliable to measure the depths of external
cracks in all types of die, regardless of the complexity of the shape or profile. Equipment deficiencies were
due to a non-conductive surface layer, which prevented the measurement, and the type of probe used was
RMSQ 0°, which was purchased for this unit. Due to the complexity of the surface and inside the cavity of
some dies, which interfered with tears from the face amount of the cell dies after probe, RMSL 90° is
suggested. Individual cracks in dies were measured and processed graphically for improved visualization
using a CAD system, where the cracks in the stamping process can be seen. The potentiometric method is
the preferable ultrasonic crack detection method to explore the depth of cracks. It clearly achieves results
faster and is more intuitive for inexperienced workers.

ACKNOWLEDGEMENTS
Work was carried out under the research grant project KEGA 069ŽU-4/2011 E-learning in the field of
particle technology and modern facility for teaching issue to enhance students' skills

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