Failure analysis of an EDM machined mold-printing die used for the production of truck spare parts |
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| Affiliation: | 1. Piraeus University of Applied Sciences, Department of Mechanical Engineering, 250 Thivon & Petrou Ralli Ave., 12244 Aegaleo, Greece;2. Stassinopoulos-Uddeholm, Steel Trading S.A., 20 Athinon Str., 18540 Piraeus, Greece;3. Technical University of Cluj-Napoca, Department of Materials Science and Engineering, 103-105 Muncii Ave., 400641 Cluj Napoca, Romania;1. Institute for Advanced Study (IUSS) of Pavia, Italy;2. University of Porto, Department of Civil Engineering, Porto, Portugal;3. University of Pavia, Department of Civil Engineering and Architecture, Pavia, Italy |
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| Abstract: | A company produces truck wheel covers as spare parts for the local market. The production of these parts is based on a progressive die performing consecutive forming and selective cutting stages throughout the initial circular steel sheet. The failure occurred to the final stage of manufacturing, as the die marks, by mold-printing, the assembly configuration of the wheel cover onto the wheel rim. The paper presents a thorough failure analysis of the broken tool. The investigation includes preliminary examination, hardness measurements and chemical analysis. In depth microscopic examination was carried out using stereoscope and optical and electron microscopy. The failure mechanism was investigated from macroscopic and microscopic perspective and conclusions regarding the crack initiation and propagation were conducted and analyzed. The causes that led to the total fracture were discussed. The design of the tool and improper surface roughness are considered to be the main causes of the failure. Some complementary recommendations were proposed so to enhance the production rate of the specific tool. |
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