FEA approach for Prediction and Validation of Die Life of Hot Forging Dies

The goal of this research was to provide a preliminary step for determining forging die life. The ability to predict failure of forging dies is very important to any industry which forges parts, or incorporates forging into part design. By predicting die failure, redesign of work piece geometry and material, die material and surface treatment, lubrication, processing temperatures can be optimized to obtain most efficient and cost effective manufacturing process. The concept die life defined as the ‘life span of die from virgin die to first repair (craking or wear). The research involves analyzing the initial effects of Friction, Workpiece temperature, Die temperature and Forging die stroke speed on effective die stresses, Die surface temperature, Die and work-piece sliding velocities, Die and work-piece contact pressure and die surface temperatures. To obtain the results, the forging process will be modeled (3D modeling software), and will be simulate (Deform software), and statically setup and examined using two level full factorial design of experiment.