Fatigue Life Investigation for Aisi-H13 Used for The Application of Pickaxe Die Using Numerical and Analytical Method
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Date
2023-04
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Addis Ababa University
Abstract
The main objective of this research was to obtain optimum forging load and temperature to investigate the fatigue life for the pickaxe piercing die made of AISI-H13 which was working under hot forging process in Kotebe Metal Tools Factory. The die supported to manufacture a pickaxe with circular whole diameter of 52mm. Under estimation of the optimum forging load, the temperature of the pickaxe piercing die, the temperature of die and work-piece, the stoke length of the forging press, press ram speed and coefficient of friction were considered as input parameters. This research approach combined analytical and numerical analysis to find a solution to set target (for estimating the forging load). The geometrical model of the dies and work-piece have been modelled using geometrical modelling software (SOLID WORK) and simulated using numerical simulation software(DEFORM-3D),wchich was adopted to simulate the forging processes using the input parameters. Then, the fatigue life of the lower die was analyzed using ANSYS software. To optimize the forging process parameters (dies and work-piece temperatures as well as coefficient of friction), the Taguchi optimization technique based on analysis of variance (ANOVA) and Analysis of mean value (ANOM) was applied. The forging process parameters were considered as experimental factors and the optimization of the forging load was considered as experimental objective. In order to obtain optimum forging load, the forging process parameters are examined using a three-level full factorial design of experiments and analyzed using MINITAB software. As an output ,the obtimum forging load,working temperature and coefficient of friction were identified with values of 2.16MN,1050C, and 0.3 respectively. Among the three forging process parameters,workpiece temperature is the most significant parameter followed by coeffiecent of friction and die temperature to get the lower required forging load.Their percentage contribution to the forging load was 61.33,37.12, and 0.87% respectively. The results of the simulation and the mathematical model were compared for validation and the identified results agreed with each other. By implementing the minimum optimized forging load(2.16 MN), the fatigue life of the lower pickaxe piercing die can be extended to 106 cycles until the die fracture.
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Keywords
forging parameters, forging load, optimization process, fatigue life, pickaxe die