Application of design of experiments to forging simulations to increase die life expectancy

Abstract Wear and fracture of steel dies employed in hot forging were evaluated through metallographic study with the aim of qualifying a Finite Element Simulation of the productive process. Apart from providing useful insights into the causes of die damaging, the simulation was exploited in a Design of Experiments to prevent fracture and to counter different mechanisms of wear. The objective is the optimization of die life acting only on process parameters that are directly adjustable in the actual industrial process. In the examination of stress distribution on the dies and the estimation of die wear, the complete forging cycle has been taken into consideration. Despite the considerable variability of the process, the study demonstrates that it is possible to prevent fracture insurgence and to increase the life expectancy of the die by a careful tuning of standard process parameters. Possible stakeholders of the study are not only process designers but also production managers, as most process parameters are modifiable during production.