August 2020 Volume 2

4. George E. Dieter, Mechanical Metallurgy , 2nd Edition, McGraw-Hill, 1976, p. 539-549. 5. R. Kohser, PhD Dissertation, Lehigh University, 1975. 6. S. Goodchild, “Forging Lubricants, Graphite or Synthetics?”, Forge Magazine, August 7, 2015. Accessed October 19, 2019 online: https://www.forgemag.com/articles/84386 forging-die-lubricants-graphite-or-synthetics. 7. A.T. Male & M.G. Cockcroft, “A Method for the Determination of the Coefficient of Friction of Metals under Conditions of Bulk Plastic Deformation”, J. Inst. Metals, 93, 1964-65, 38.

FORGING RESEARCH

Fig 1 – (a) Schematic representation of a cross-section of a ring before, top, and after, below, forging, showing the difference in deformation behavior as a function of friction conditions. (b) Decrease in internal diameter versus deformation percent (reduction in height) analytically determined calibration curves [6].

Fig 1 – (a) Schematic representation of a cross-section of a ring before, top, and after, below, forging, showing the difference in deformation behavior as a function of friction conditions. (b) Decrease in internal diameter versus deformation percent (reduction in height) analytically-determined calibration curves [6]. (b) Fig 1 – (a) Schematic representation of a cross-section of a ring before, top, and after, below, forging, showing the difference in deformation behavior as a function of friction conditions. (b) Decrease in internal diameter versus deformation percent (reduction in height) analytically determined calibration curves [6]. (a)

(a) (b) Fig 2 – (a) Ring-test die design with removable inserts for pre-heating and/or surface treatments. (b) Manufactured dies with representative inserts. Die body is 4140 steel, and die inserts are H13 heat treated to 42 HRC. Die inserts are 3 inches in diameter.

Fig 2 – (a) Ring-test die design with removable inserts for pre-heating and/or surface treatments. (b) Manufactured dies with representative inserts. Die body is 4140 steel, and die inserts are H13 heat treated to 42 HRC. Die inserts are 3 inches in diameter. (b) Fig 2 – (a) Ring-test die design with removable inserts for pre-heating and/or surface treatments. ( ) Manufactured dies with representative inserts. Die body is 4140 ste l, and die inserts are H13 heat treated to 42 HRC. Die inserts are 3 inches in diameter. (a)

Temperature, °C/°F

Friction Factor, m

Lubricant

None

23/73

0.80

Lubricant Graphite MoS 2 Graphite None MoS 2 Graphite Graphite MoS 2 MoS 2 Graphite

Temperature, °C/°F 23/73 23/73

Friction Factor, m 0.30 0.12

23/73 23/73 23/73 100/212 200/392 2 0/392 100/212

0.30 0.18 0.80

0.80 0.30 0.12 0.30 0.18 0.80 0.38

.38

100/212 100/212 200/392 200/392

(a)

(b)

MoS 2

Graphite

MoS 2

(a)

(b)

Fig 3 – (a) Results of room temperature ring tests evaluating the effect of lubricant on friction conditions, (b) summary of results from room temperature and elevated temperature tests with and without lubricant, (c) results of tests using graphite lubricant at 25, 100 and 200°C, and (d) results of tests using MoS2 lubricant at 25, 100 and 200 °C. (d) Fig 3 – (a) Results of room temperature ring tests evaluating the effect of lubricant on friction conditions, (b) summary of results from room temperature and elevated te perature tests with and without lubricant, (c) results of tests using graphite lubricant at 25, 100 and 200°C, and (d) results of tests using MoS 2 lubricant at 25, 100 and 200 °C. (c)

FIA MAGAZINE | AUGUST 2020 55