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Simulation-assisted approach for determining wear-limited tool life in the coining process

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Abstract

Efficiency of coin manufacturing is often limited by the service life of the stamping dies, whose degradation by wear results in decreasing the quality of the produced coin engraving. The aim of this work is to explore the ability of the combined application of experimental characterization and numerical simulation of the material elastoplastic forming response, friction effects, and die material wear rate as a tool to contribute to the coin design in order to ultimately increase the number of coins that can be die forged before the use of a worn die compromises the desired quality of the final product. The following aspects have been particularly addressed in this study. First, the influence of two design parameters related with the quality of the coins, i.e., die displacement and depth of engraving, is quantified determining that the die displacement is the most preponderant since the stamping force needed in this process is higher compared with that obtained by varying the depth of engraving. In addition, it is found that the curvature of the coin relief determines the local stress distribution, in some cases even at the opposite die, resulting in a heterogeneous wear evolution. A complementary wear test reveals that, for the involved range of curvatures, the wear mechanism may shift from dominated by plowing/cutting to dominated by fatigue. It is concluded that the numerical simulation allows considering efficiency of the coining process already at the stage of the aesthetic design of a coin.

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Acknowledgments

Special thanks to Javiera Aguirre for the SEM characterization conducted during her internship at the Max-Planck Institut for Iron Research, Düsseldorf, Germany. Pedro Renato T. Avila from the São Carlos School of Engineering, University of São Paulo, Brazil, is thankfully acknowledged for facilitating and helping the the pin-on-disc testing and FEG-SEM analyses of the wear scars. Prof. Haroldo Pinto is a CNPq fellow.

Funding

The authors received support from the National Agency for Research and Development (ANID) through Fondecyt Grant 1180591, FONDEQUIP Grant EQM160091, FONDEQUIP EQM150016 and ANID PFCHA/Doctorado Becas Chile/2019-21190623.

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Authors and Affiliations

  1. Departamento de Ingeniería Mecánica, Universidad de Santiago de Chile, USACH, Av. Bernardo O’Higgins 3363, Santiago de Chile, Chile

    Álvaro Navarrete, Miguel López & Claudio García-Hererra

  2. Departamento de Ingeniería Mecánica y Metalúrgica, Pontificia Universidad Católica de Chile, Av. Vicuña Mackenna 4860, Santiago de Chile, Chile

    José Miguel Izquierdo, Diego Celentano & Magdalena Walczak

  3. Centro de Investigación en Nanotecnología y Materiales Avanzados (CIEN-UC), Pontificia Universidad Católica de Chile, Av. Vicuña Mackenna 4860, Santiago de Chile, Chile

    Diego Celentano & Magdalena Walczak

  4. Departament of Materials Engineering, São Carlos School of Engineering, University of São Paulo, Av. Joao Dagnone 1100, 13563–120, São Carlos, SP, Brazil

    Haroldo Cavalcanti Pinto

Authors
  1. Álvaro Navarrete
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  2. José Miguel Izquierdo
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  3. Miguel López
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  4. Diego Celentano
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  5. Magdalena Walczak
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  6. Claudio García-Hererra
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  7. Haroldo Cavalcanti Pinto
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Correspondence to Diego Celentano.

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Navarrete, Á., Izquierdo, J.M., López, M. et al. Simulation-assisted approach for determining wear-limited tool life in the coining process. Int J Adv Manuf Technol 111, 2243–2257 (2020). https://doi.org/10.1007/s00170-020-06228-3

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