Fracture mechanics based life prediction of hollow extrusion dies

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Hot metal extrusion dies, especially for hollow profiles, are quite costly. Repair or replacement of dies and affiliated tooling adds to the cost, brings down productivity, and can contribute to product defects. Reasons for the high production and maintenance cost are stringent material requirements (highstrength and high-hardness tool steels), precision manufacturing methods (spark erosion, wire EDM, etc), and a series of specialized heat treatment and surface hardening operations. Consequently, a major goal for die designers and manufacturers is longer service life. An equally important objective is a reasonably accurate prediction of time-to-failure, to help devise an optimum replacement and inventory strategy, and for good performance evaluation. Majority of hot-work extrusion dies fail by fatigue fracture. Treating the die as a flat plate with edge crack, a fracture mechanics based fatigue life prediction model was developed by the authors in an earlier work. To improve the precision of die life prediction, a hollow (tube) extrusion die is modeled in the current work as a pressurized cylinder with internal crack. Based on this new strategy, a model is developed to forecast fracture failure of extrusion dies. Stochastic nature of various fatigue related die parameters is examined. Monte Carlo simulation is used for die life prediction under a given set of operating conditions and mechanical properties. Simulated fracture life values thus obtained are quite realistic in comparison with actual extrusion die life data from the industry.

Original languageEnglish
Title of host publicationASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)
Pages1719-1725
Number of pages7
Volume3
EditionPARTS A, B, AND C
DOIs
Publication statusPublished - 2012
EventASME 2012 International Mechanical Engineering Congress and Exposition, IMECE 2012 - Houston, TX, United States
Duration: Nov 9 2012Nov 15 2012

Other

OtherASME 2012 International Mechanical Engineering Congress and Exposition, IMECE 2012
CountryUnited States
CityHouston, TX
Period11/9/1211/15/12

Fingerprint

Extrusion dies
Fracture mechanics
Fatigue of materials
Metal extrusion
Cracks
Tool steel
Electric sparks
Service life
Hardening
Costs
Erosion
Repair
Productivity
Hardness
Heat treatment
Wire
Mechanical properties
Defects
Industry

ASJC Scopus subject areas

  • Mechanical Engineering

Cite this

Qamar, S. Z. (2012). Fracture mechanics based life prediction of hollow extrusion dies. In ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE) (PARTS A, B, AND C ed., Vol. 3, pp. 1719-1725) https://doi.org/10.1115/IMECE2012-93109

Fracture mechanics based life prediction of hollow extrusion dies. / Qamar, Sayyad Zahid.

ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE). Vol. 3 PARTS A, B, AND C. ed. 2012. p. 1719-1725.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Qamar, SZ 2012, Fracture mechanics based life prediction of hollow extrusion dies. in ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE). PARTS A, B, AND C edn, vol. 3, pp. 1719-1725, ASME 2012 International Mechanical Engineering Congress and Exposition, IMECE 2012, Houston, TX, United States, 11/9/12. https://doi.org/10.1115/IMECE2012-93109
Qamar SZ. Fracture mechanics based life prediction of hollow extrusion dies. In ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE). PARTS A, B, AND C ed. Vol. 3. 2012. p. 1719-1725 https://doi.org/10.1115/IMECE2012-93109
Qamar, Sayyad Zahid. / Fracture mechanics based life prediction of hollow extrusion dies. ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE). Vol. 3 PARTS A, B, AND C. ed. 2012. pp. 1719-1725
@inproceedings{112f82390cf44adead5351f16fca8c55,
title = "Fracture mechanics based life prediction of hollow extrusion dies",
abstract = "Hot metal extrusion dies, especially for hollow profiles, are quite costly. Repair or replacement of dies and affiliated tooling adds to the cost, brings down productivity, and can contribute to product defects. Reasons for the high production and maintenance cost are stringent material requirements (highstrength and high-hardness tool steels), precision manufacturing methods (spark erosion, wire EDM, etc), and a series of specialized heat treatment and surface hardening operations. Consequently, a major goal for die designers and manufacturers is longer service life. An equally important objective is a reasonably accurate prediction of time-to-failure, to help devise an optimum replacement and inventory strategy, and for good performance evaluation. Majority of hot-work extrusion dies fail by fatigue fracture. Treating the die as a flat plate with edge crack, a fracture mechanics based fatigue life prediction model was developed by the authors in an earlier work. To improve the precision of die life prediction, a hollow (tube) extrusion die is modeled in the current work as a pressurized cylinder with internal crack. Based on this new strategy, a model is developed to forecast fracture failure of extrusion dies. Stochastic nature of various fatigue related die parameters is examined. Monte Carlo simulation is used for die life prediction under a given set of operating conditions and mechanical properties. Simulated fracture life values thus obtained are quite realistic in comparison with actual extrusion die life data from the industry.",
author = "Qamar, {Sayyad Zahid}",
year = "2012",
doi = "10.1115/IMECE2012-93109",
language = "English",
isbn = "9780791845196",
volume = "3",
pages = "1719--1725",
booktitle = "ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)",
edition = "PARTS A, B, AND C",

}

TY - GEN

T1 - Fracture mechanics based life prediction of hollow extrusion dies

AU - Qamar, Sayyad Zahid

PY - 2012

Y1 - 2012

N2 - Hot metal extrusion dies, especially for hollow profiles, are quite costly. Repair or replacement of dies and affiliated tooling adds to the cost, brings down productivity, and can contribute to product defects. Reasons for the high production and maintenance cost are stringent material requirements (highstrength and high-hardness tool steels), precision manufacturing methods (spark erosion, wire EDM, etc), and a series of specialized heat treatment and surface hardening operations. Consequently, a major goal for die designers and manufacturers is longer service life. An equally important objective is a reasonably accurate prediction of time-to-failure, to help devise an optimum replacement and inventory strategy, and for good performance evaluation. Majority of hot-work extrusion dies fail by fatigue fracture. Treating the die as a flat plate with edge crack, a fracture mechanics based fatigue life prediction model was developed by the authors in an earlier work. To improve the precision of die life prediction, a hollow (tube) extrusion die is modeled in the current work as a pressurized cylinder with internal crack. Based on this new strategy, a model is developed to forecast fracture failure of extrusion dies. Stochastic nature of various fatigue related die parameters is examined. Monte Carlo simulation is used for die life prediction under a given set of operating conditions and mechanical properties. Simulated fracture life values thus obtained are quite realistic in comparison with actual extrusion die life data from the industry.

AB - Hot metal extrusion dies, especially for hollow profiles, are quite costly. Repair or replacement of dies and affiliated tooling adds to the cost, brings down productivity, and can contribute to product defects. Reasons for the high production and maintenance cost are stringent material requirements (highstrength and high-hardness tool steels), precision manufacturing methods (spark erosion, wire EDM, etc), and a series of specialized heat treatment and surface hardening operations. Consequently, a major goal for die designers and manufacturers is longer service life. An equally important objective is a reasonably accurate prediction of time-to-failure, to help devise an optimum replacement and inventory strategy, and for good performance evaluation. Majority of hot-work extrusion dies fail by fatigue fracture. Treating the die as a flat plate with edge crack, a fracture mechanics based fatigue life prediction model was developed by the authors in an earlier work. To improve the precision of die life prediction, a hollow (tube) extrusion die is modeled in the current work as a pressurized cylinder with internal crack. Based on this new strategy, a model is developed to forecast fracture failure of extrusion dies. Stochastic nature of various fatigue related die parameters is examined. Monte Carlo simulation is used for die life prediction under a given set of operating conditions and mechanical properties. Simulated fracture life values thus obtained are quite realistic in comparison with actual extrusion die life data from the industry.

UR - http://www.scopus.com/inward/record.url?scp=84887283540&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84887283540&partnerID=8YFLogxK

U2 - 10.1115/IMECE2012-93109

DO - 10.1115/IMECE2012-93109

M3 - Conference contribution

AN - SCOPUS:84887283540

SN - 9780791845196

VL - 3

SP - 1719

EP - 1725

BT - ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)

ER -