Developing Molds to Increase the Production Process of Automotive Parts in the Hot Forging Process Using the Finite Element Method

This study investigates the wear patterns of hot forging dies in relation to work-piece temperature, die temperature, and the coefficient of friction. The materials used in the forging process were tool steel grade SKD61 for the dies and general-purpose high-tensile steel with medium strength, grade SCM435, for the work-pieces. The initial sizing of workpieces is 13 mm in diameter and 155 mm in length. The simulation of the forging process was carried out using commercially available software based on the finite volume method. Characteristic values of the parameters in the simulation started with die temperatures of 120 ℃ and 180 ℃, and workpiece temperatures of 850 ℃, 950 ℃, 1050 ℃, and 1150 ℃, respectively. The friction coefficient values used were 0.2, 0.3, and 0.4. The experimental results indicated that at a workpiece temperature of 1150 ℃ and die temperature of 180 ℃, a minimum forging force of 132 KN was required to achieve the desired complete shape in close die forging while minimizing flash. Therefore, the contact pressure distribution stress on the workpiece remained within the fracture threshold curve region due to the minimum operation force during the process. The simulation of the forging process indicated that appropriate parameter adjustments contributed to the reduction of wear mechanisms. By way of comparing the numerical results with the measurements taken from the worn die, the damage coefficient has been evaluated for one of a kind points at the die floor, and a very last value of wear is usually recommended.