Wear analysis of forging tools used in the hot forging processes using 3D reverse scanning techniques and cooling-lubricating system

This article presents a wear analysis of die inserts used in the hot forging process of manufacturing a yoke type forging—an element applied in the steering systems of passenger vehicles. The studies involved the application of an original reverse scanning method intended for a fast and reliable wear analysis of the forging tools (of complicated shapes), affording an easy assessment, without the need to dismount the tools from the forging unit. The research is based on measurements (scans) of forgings periodically collected from the process and constitutes a useful tool for measuring and testing. In addition to the industrial forging process, a new lubrication-cooling system has been developed to enable an investigation of the effect of the amount and frequency of lubrication on the tool wear, as well as to determine the optimum lubrication parameters to ensure repeatability of the forging process. The preliminary results show the possibility of using an extended method to analyze the lifetime of forging tools, including tools with complex geometry, as well as introducing a new forging and stabilizing process of the lubricating and cooling devices. The results of the research have shown that the use of the inverse scanning method enables a real-time practical control of the state of the forging tools. In addition, the device is designed to select and provide the optimum tribological conditions of the process. Both proposed solutions should have a positive impact on the improvement of the production output and the reduction of the production costs.