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Report No. : R&D/001/2011 dated: 6 Sept 2011

Chapter 1 Introduction
1.1 Application of HSS
Since t e !irt of t e nineteent century" i# $%peed %teel (&SS) a'e under#one continuou% i(pro'e(ent and t eir u%e a% increa%ed in (anufacturin# #ood )uality %teel product%. *t pre%ent" &SS a% t e tool (aterial %till occupy an i(portant po%ition. + ey are re)uired a% one of t e core (aterial for (anufacturin# (ac ine co(ponent%. &SS not only a'e e,cellent i# te(perature ardne%%" -ear re%i%tance and tou# ne%% !ut al%o a'e a i# (ac ina!lility. + ey are (ainly u%ed a% (ac ine cuttin# tool%" %o(e for t e cold (old" roll% for pla%tic defor(ation and ot er proce%%in# tool%" a% -ell a% for co(ponent% - ic re)uire %pecial propertie% li.e i# $ te(perature ardne%% and -ear re%i%tance durin# t eir %er'ice life" %uc a% %lidin# 'ane air co(pre%%or%" pu(p% oil no//le 'al'e" i# te(perature !earin#%" etc. 0it (odern (anufacturin# tec nolo#y de'elop(ent" t e application% of &SS continue to e,pand. 1n addition to t e a!o'e product%" t eir u%e in (anufacturin# die%" tool% and -ear part% i% #radually increa%in#

1.2 Classification of HSS

On t e !a%i% of production proce%%" &SS i% di'ided into t e con'entional &SS (Con'. &SS) and po-der (etallur#y i# $%peed %teel (23 &SS). 456 7urt er cla%%ification a% !een % o-n in t e 7i# . 1.1

&SS

Con'entional &SS

2o-der 3etallur#y &SS

&SS 8

&SS 9

&SS :

&i# Co (;<.=>)

&i# *l

&i# ? (;2.=>)
Fig1.1 General classification of High Speed steels [9]

1t i% i(portant to note t at all &i# %peed %teel% are #enerally i# car!on %teel% (;0.@>). + e (aAor alloyin# ele(ent% are t e %ta!le car!ide for(in# ele(ent% (al%o called refractory ele(ent%) li.e 0" 3o" ? and Cr. + e ardne%% 'alue% of (atri, o!tained after )uenc in# and te(perin# i% in t e ran#e of Rc 60$6=" and t i% i% retained e'en at i# te(perature% (nearly 600 BC). + e co(po%ition !y -ei# t > of t e %teel (*S2 20C0) u%ed in t i% %tudy i% #i'en in +a!le 1.1 !elo-

C 1.2D

Cr <.2

3o =.0

0 6.<

Co D.=

? C.1

7e !alance

Table 1.1 Composition of ASP !"! [1]

1. Hi!h Speed Steel "# Po$der %etallur!#

Re%earc and de'elop(ent %tarted a!out 156= on po-der (etallur#y proce%%in# of &i# %peed %teel%. + e o!Aecti'e% -ere to i(pro'e t e functional propertie% and perfor(ance of &SS in de(andin# application% and t u% increa%e t e co(petiti'ene%% of &SS 'er%u% ce(ented car!ide% pri(arily in (ac inin# operation%. + e R&D -or. -a% focu%ed on t e production of fully den%e &SS !illet% and ot -or.ed %e(i$fini% ed product% u%in# t e (anufacturin# route: (eltin#E inert #a% (nitro#en) ato(i/ationE po-der encap%ulationE ot i%o%tatic pre%%in#. 2a#e 1 of &
Fig 4.3 (d) Die load and punch load in trimming operation (face angle = 5)

(ln F2$ ln F1) au%tenite

ferrite

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Report No. : R&D/001/2011 dated: 6 Sept 2011

FAC# A$G%#&'

3rd STN EFFECTIVE PLASTIC STRAIN

rd

3rd STN EFFECTIVE STRESS

Fig. 4.4 (a)Effective plastic strain and stress in 3 station trimmed bolts (face angle = )

3RD STN HEX TRIM DIE STRESS ANALYSIS (FACE ANGLE = 7 )

Fig. 4.4 (b) !tress anal"sis of #!$ %&3& trim dies (face angle = )

2a#e 2 of &

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Fig. 4.5 (a)Effective plastic strain and stress in 3rd station trimmed bolts (face angle ='5)

3RD STN HEX TRIM DIE STRESS ANALYSIS (FACE ANGLE = 15 )

Fig. 4.5 (b) !tress anal"sis of #!$ %&3& trim dies (face angle = '5)

3RD STN HEX TRIM DIE TANGENTIAL STRESS ANALYSIS (FACE ANGLE = 15 )

Fig. 4.5 (c) (angential stresses generated during trimming in trim dies (face angle = '5)

2a#e of &

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3RD STN HEX TRIM DIE STRESS ANALYSIS (FACE ANGLE = 26 )

Fig. 4.) (b) !tress anal"sis of #!$ %&3& trim dies (face angle = %))

3RD STN HEX TRIM DIE TANGENTIAL STRESS ANALYSIS (FACE ANGLE = 26 )

Fig. 4.) (c) (angential stresses generated during trimming in trim dies (face angle = %))

2a#e + of &

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3RD STN HEX TRIM DIE STRESS ANALYSIS (FACE ANGLE = 3% )

Fig. 4. (b) !tress anal"sis of #!$ %&3& trim dies (face angle = 3&)

3RD STN HEX TRIM DIE TANGENTIAL STRESS ANALYSIS (FACE ANGLE = 3% )

Fig. 4. (c) (angential stresses generated during trimming in trim dies (face angle=3&)

2a#e , of &
MAX" LOAD 2$"6% T

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+., Su--ar# of results'

+ e %i(ulation re%ult% are a% follo-%: (+a!le <.=)
P&r&'()(r (M&*") 3rd S&)+,Prod0ct Stress ,*paProd0ct Strain Trim +ie Stress ,*pa8 Force ,Ton%. 11".2! 1.44 "" 1.!! 9."3 5. 11".3! 1.4' 91".!! 3! . ! H(* Tr+' D+( F&/( A-01( 7. 11". ! 1.44 1%. 11 .!! 1.4! 15. 111.!! 1.32 26. 1!3."! 1. 9 3%. 1!!.4! 1.11

31.!! 1'1!.!! 1'19.!! .3'51!6' "' 1.!! 23".1! 149.11 1!!.2! "". 3 .1951!61 339.3! "1.21 1.4!

Tangential Stress 7n +ie 312.!!

"1.!! "1.2! "".2! (able 4.5 !imulation results

7i# <.D % o-% t e plot of tri( die %tre%% ?/% face an#le for *S2 20C0 (aterial (ade tri( die%
T()* +)# ST(#SS,*Pa- ./S FAC# A$G%#

Fig 4.* #!$ %&3& trim die stress +,! face angle -t is evident from the above figures that the trim die stress and tangential stress on die is negligible (approaches &) for a face angle of %). For all other values of face angles. the die stress is

+.. Co-parison of tri- die -aterials "# si-ulation /Stress anal#sis0

1n t i% %ection" -e a'e tried to co(pare *S2 20C0 and car!ide (G+$==) (aterial (ade tri( die% !y co(parin# t e %tre%%e% #enerated in t e( durin# tri((in# operation. + e propertie% of ra- (aterial (*$2D6) -ere already #i'en in +a!le <.< a!o'e. +a!le <.6 !elo- % o-% a co(pari%on !et-een *S2 20C0 and car!ide (aterial propertie%. PROPERTIES CAR1IDE ASP22 2 HOINGS 3ODI9IS 200000 3pa 2<00003pa 2O1SSONJS R*+1O 0.C 0.C
D:NS1+H +&:R3*9 CONDIC+1?1+H S2:C171C &:*+ C*2*C1+H 31N13I3 H1:9D S+R:SS (S) H1:9D CONS+*N+ ( C)2a#e . of & O77S:+ (*) S+R*1N &*RD. :L2. (N) @D=0 .#/( <6.0 0att/(K <20 8oule/.#K <10000 3pa 5C<5C0 3pa $$ 0.1@5
$00= C

D100 .#/( 2< 0att/(BC <20 8/K#BC 100000 3pa 200000 3pa 0 0 1.11 e
$00=

CO:77. O7 +&:R3*9 :L2*NS1ON 1.= e

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Fig 4./(b) !tress anal"sis of carbide trim dies (face angle = '&)

Report No. : R&D/001/2011 dated: 6 Sept 2011

0e a'e al%o perfor(ed tan#ential %tre%% analy%i%" t e re%ult% of - ic are % o-n in 7i# <.@ (a) & ! !elo-

3RD STN HEX TRIM DIE TANGENTIAL STRESS ANALYSIS (ASP 2%3%)
Fig 4.'& (a) (angential stresses generated during trimming in #!$ %&3& trim dies (face angle='&)

3RD STN HEX TRIM DIE TANGENTIAL STRESS ANALYSIS (CAR2IDE)

Para-eter /%a3.0

DIE %ATERIA4

Fig 4.'& (b) (angential stresses generated during carbide made trim 2 dies in trimming operation (face angle='&) rd Sation ASP 22 CAR1IDE

+ri( Die Stre%% (32a) +.) Results of tri- die -aterial co-parison

1@D0.00 <C5.50 + e re%ult% of die (aterial co(pari%on for a face 2a#e an#le) of 10B of & i% % o-n in +a!le <.@ !elo+an#ential Stre%% On Die (32a) 165.D1 162.D0

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2a#e & of &