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Hot forging dies are subjected to high cyclic thermo-mechanical loads. In critical areas, the occurring stresses can exceed the material’s yield limit. Additionally, loading at high temperatures leads to thermal softening of the used martensitic materials. These effects can result in an early crack initiation and unexpected failure of the dies, usually described as thermo-mechanical fatigue (TMF). In previous works, a temperature-dependent cyclic plasticity model for the martensitic hot forging tool steel 1.2367 (X38CrMoV5-3) was developed and implemented in the finite element (FE)-software Abaqus. However, in the forging industry, application-specific software is usually used to ensure cost-efficient numerical process design. Therefore, a new implementation for the FE-software Simufact Forming 16.0 is presented in this work. The results are compared and validated with the original implementation by means of a numerical compression test and a cyclic simulation is calculated with Simufact Forming.
Ein tiefgreifendes Verständnis des zyklischen Plastizitätsverhaltens metallischer Werkstoffe ist sowohl für die Optimierung der Materialeigenschaften als auch für die industrielle Auslegung und Fertigung von Bauteilen von hoher Relevanz. Insbesondere moderne Legierungen wie Duplex-Stähle zeigen unter Lastumkehr aufgrund des komplexen mehrphasigen Gefüges sowie der Neigung zu verschiedenen Ausscheidungsreaktionen einen ausgeprägten Bauschinger-Effekt, welcher bei technischen Umformvorgängen berücksichtigt werden muss. Der Bauschinger-Effekt begründet sich maßgeblich in der Entstehung von Rückspannungen, welche aus dem unterschiedlichen Plastizitätsverhalten der austenitischen und ferritischen Phase resultieren. Instrumentierte Mikroindenter-Versuche in ausgewählten Ferrit- und Austenitkörnern haben gezeigt, dass austenitische Gefügebestandteile durch einen deutlich früheren Fließbeginn sowie eine stärkere Rückplastifizierung während der Entlastung charakterisiert sind. Zudem wurde nachgewiesen, dass Ausscheidungen im Rahmen einer 475°C-Versprödung diesen Phasenunterschied verstärken und somit in einem höheren Bauschinger-Effekt resultieren.
Hot work tools are subjected to complex thermal and mechanical loads during hot forming processes. Locally, the stresses can exceed the material’s yield strength in highly loaded areas as e.g. in small radii in die cavities. To sustain the high loads, the hot forming tools are typically made of martensitic hot work steels. While temperatures for annealing of the tool steels usually lie in the range between 400 and 600 °C, the steels may experience even higher temperatures during hot forming, resulting in softening of the material due to coarsening of strengthening particles. In this paper, a temperature dependent cyclic plasticity model for the martensitic hot work tool steel 1.2367 (X38CrMoV5-3) is presented that includes softening due to particle coarsening and that can be applied in finite-element calculations to assess the effect of softening on the thermomechanical fatigue life of hot work tools. To this end, a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is coupled with a cyclic plasticity model with kinematic hardening. Mechanism-based relations are developed to describe the dependency of the mechanical properties on carbide size and temperature. The material properties of the mechanical and kinetic model are determined on the basis of tempering hardness curves as well as monotonic and cyclic tests.