Prediction of tool wear and tool life by experiment/modeling/simulation of the die compaction process

Prediction of tool life caused by tool wear is of great importance during die compaction processes in the powder metallurgy industry. In this study, experiment, modeling, and simulation are integrated to predict tool wear and life of the die. We utilized a specially-modified, "pin-onflat" reciprocating test to quantify the amount of tool wear with a matrix of experiments consisting of three tool materials and two mixture powders. The modified "loop test" is also employed to provide comparison results. We propose the new model of "wear work" by integration of frictional stress multiplied by velocity with respect to contact area and time. By combining wear data with information on the hardness of the die materials, we can predict tool wear and life. For complex components, the finite element simulation is used to calculate the wear work and to select critical factor with sensitivity analysis concept.