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Optimization of cold forging process technology by means of simulation

The paper presents an approach to increasing of cold and warm forging process quality and economical efficiency by means of computer simulation. The main ways for achieving of stable product quality, long tool life and high accuracy are analysed. The technology improvement is reached by modification of perform and die design that eliminates flow induced defects, reduces stress concentration in critical areas through optimising of fillets and/or introducing splits in combination with shrink rings and hard inserts. Finite element simulation allows finding optimal value of interference that provides compressive stress state in hard but fragile inserts under actual forging load. Simulation also generates profiled shape of the die that compensates elastic deformation of tooling set and provides precise geometrical accuracy of a forged part. Ductile fracture of the forged part can be predicted and minimised by means of simulation. Presented model is realised in commercial metal forming simulation program QForm.