Steel forging tools are subjected to a number of tribological wear mechanisms depending on the geometry and surface of the tool and the flow of the material. Thus, there is no single general tribological wear mechanism, and only the predominant wear mechanisms in this case can be indicated. The problem has been known for years, but due to its complexity research on it is still relevant. In this study, the various wear mechanisms of hot work tools are analyzed on the basis of original research. Moreover, the influence of the micro- and macrostructure of the material and of its mechanical, physical, and technological characteristics on susceptibility to a given type of wear is considered. Adhesive wear, wear caused by plastic deformation, mechanical fatigue, thermal fatigue, the influence of hardness, heat treatment, and impact strength on tool wear and the mechanisms causing this wear are discussed in addition to tribological wear mechanisms such as abrasive wear. The influence of thermomechanical history and the characteristics of the tool material, including structural anisotropy, on the wear of these tools is indicated. The analysis of wear mechanisms performed will enable more precise definition of the principles of tool material selection and tool material condition for the hot forging of steel.

The paper presents the results of tests on a die insert made of non-standardised chrome-molybdenum–vanadium tool steel used during pre-forging, the life of which was 6000 forgings, while the average life for such tools is 8000 forgings. It was withdrawn from production due to intensive wear and premature breakage. In order to determine the causes of increased tool wear, a comprehensive analysis was carried out, including 3D scanning of the working surface; numerical simulations, with particular emphasis on cracking (according to the C-L criterion); and fractographic and microstructural tests. The results of numerical modelling in conjunction with the obtained results of structural tests allowed us to determine the causes of cracks in the working area of the die, which were caused by high cyclical thermal and mechanical loads and abrasive wear due to intensive flow of the forging material. It was found that the resulting fracture initiated as a multi-centric fatigue fracture continued to develop as a multifaceted brittle fracture with numerous secondary faults. Microscopic examinations allowed us to evaluate the wear mechanisms of the insert, which included plastic deformation and abrasive wear, as well as thermo-mechanical fatigue. As part of the work carried out, directions for further research were also proposed to improve the durability of the tested tool. In addition, the observed high tendency to cracking of the tool material used, based on impact tests and determination of the K_1C fracture toughness factor, led to the proposal of an alternative material characterised by higher impact strength.

Hot deformation behavior of 4130 steel and optimization of its processing parameters are presented in this paper. Compression tests were performed at temperatures ranging from 800 to 1200 °C and at the strain rates in the range from 0.01 to 100 s⁻¹. A comprehensive analysis of the material behavior at different temperature and strain-rate ranges was performed taking into account various criteria of stability and instability of the material flow under various thermomechanical conditions. The flow–stress curves obtained during compression tests, as well as the processing maps elaborated on the basis of various flow–stability criteria, are discussed. Processing parameters developed according to the Prasad’s and Murty’s criteria are recommended for designing the technology of forging of the investigated steel. Such parameters ensure the homogeneity and stability of the material flow in a forged part, what was confirmed by successful forging of 4130 steel in industrial conditions. The processing map developed according to Gegel’s approach, as compared to the processing maps obtained in accordance with the Prasad’s and Murty’s criteria, should be treated as general support for determining the thermomechanical processing parameters.

Tool life in plastic forming processes is a problem of the utmost importance as it significantly affects the cost of production. Hot forging with hammers and mechanical presses is an example of the technological process in which the load on tools is extremely high and, consequently, the lifetime of tools is short. Considering, additionally, that this applies to large-scale production, from an economic point of view, the key issue will be to extend the tool life, make an accurate prediction of the number of parts that can be forged before the replacement of dies is necessary, and develop a system for quick tool changeover. Initially, however, it is necessary to understand the causes of excessive tool wear, which may lie in phenomena occurring at the level of microstructure. The aim of this article was to outline an example of the coexistence of multiple wear mechanisms in hot forging dies. For the modified chemical composition, the microstructure examinations were performed in selected areas of the tool. The research has revealed the causes of cracks in tools and some irregularities in the preparation of tools for production process.

Warm forging brings together advantages of hot (e.g. forging load reduction) and cold (e.g. no scale) metal forming operations. However, due to decreasing the process temperature, the risk of fracture occurrence increases. In this paper the risk of cracking initiation during warm forging of surgical forceps made of martensitic stainless steel is estimated. The investigations assume the analysis of the fracture initiation point in the component during forging and attempt to define the critical value of process parameters by means of laboratory tests and FEM numerical simulation.

Perceptive review of augmented reality applications in the forging industry is the primary goal of the paper. The differences between the Virtual (VR) and Augmented (AR) realities are highlighted first. Examples of the AR technology’s various industrial applications are then presented, which is followed by the evaluation of capabilities of the approaches in the forging industry. The two practical case study solutions were implemented, and their operational capabilities under industrial conditions were tested. Examples of obtained results are presented within the paper.