Wear Prediction in Oscillating Cold Forging Processes

Abstract

Abstract Oscillating forming processes allow forming with reduced process forces when liquid lubricants are used. They are industrially applied as oscillating cold forging processes for the production of splines. Previous investigations revealed that the force reduction is provoked by relubrication of the workpiece—tool contact zone. So far, the effect of the oscillation on tool wear remains unknown. The results presented in this paper show that the wear critical region of the tool is the calibration zone. Tool wear is emulated on a test bench under loads of representative cold forging processes. The results disclose several relevant phenomena. Friction conditions can vary considerably in the course of the oscillations. Wear protection layers are effective measures to prolong tool life also under these conditions. Prediction of wear development based on established models fails due to neglecting the local state of lubrication. Graphical Abstract