Precision Forging Technology

Tool wear is a major concern in the metal forming industry, especially in hot and warm forging, where the die surfaces are subjected to high temperatures and pressures with sliding contact. Additionally, the die surface is subject to thermal fatigue because of lubricant application (alternate heating and cooling). The elevated interface temperatures may also result in tempering of the die surface resulting in a drop in hardness and subsequent increase in tool wear. Costs associated with tool wear include:

a)      press downtime
b)      die rework/remanufacturing costs
c)      increase in product rejection rate

The ERC/NSM has significant experience in the area of tool wear studies in forging (http://nsm.eng.ohio-state.edu/html/f-reports.html). In collaboration with a number of companies, the ERC/NSM has submitted a proposal to the Forging Industry Education & Research Foundation (FIERF) (www.forging.org ) for application of advanced ceramic inserts and coating for improving die service life in hot and warm forging.

We are delighted that FIERF decided to fund our proposal and the study has started in July 2006.

This study will rely on participation by interested forging companies to run tool wear studies under realistic production conditions on selected parts or part families. Kennametal, Inc., a leader in advanced tool materials and coatings, agreed to work closely with us on this project. In addition, the following forging and lubrication systems companies have expressed interest in participating in this project:

a)      Acheson Industries (www.achesonindustries.com)

b)   American Axle and Manufacturing (www.aam.com)

c)   Ashland Precision Tooling (http://www.aptooling.com/)

d)     Bharat Forge America (www.bharatforgeamerica.com)

e)   Bohler-Uddeholm (http://www.bohler-uddeholm.com/)

f)   Eaton Truck Components (http://truck.eaton.com/)

g)   Fuchs Lubricants

h)   Hirschvogel Inc. (www.hirschvogel.de)

i)    Impact Forge (http://www.impactforge.com/)

j)    Orchid Stealth Orthopedic Solutions

k)   Queen City Forging Co. (www.qcforge.com)

l)      Walker Forge (www.walkerforge.com)

m)    Walter Metals Corp (http://www.waltermetals.com/)

To review the PROJECT PLAN, please click here.

The PROGRESS REPORTS AND RESULTS of the project are available to participating companies and are accessible with a user name & password

User Name: 

Password:   

Interested forging and lubrication companies, please contact Manas Shirgaokar (Shirgaokar.1@osu.edu) or Dr. Taylan Altan (altan.1@osu.edu ) for further information.