Forging Die Wear Optimization: A Combined Approach with Finite Element Analysis and Taguchi Methodology

Forging dies serve as essential tools in shaping workpieces during the forging process to achieve the desired shape and geometry. In hot forging processes, wear is a significant concern due to the high temperatures involved. The repeated contact between the die and the hot workpiece can lead to abrasive and adhesive wear, where material is gradually removed from the die surface. This wear directly impacts the overall production cost. It also affects the shape, dimensions, and surface quality of the final product. The present study focuses on a comprehensive wear analysis of a hot forging die. The influence of critical process variables, including billet temperature, die temperature, friction coefficient, and percentage deformation on die wear, was examined. Employing three-dimensional finite element analysis with DEFORM software, the study utilizes the Taguchi experimental method to systematically design parametric combinations. Analysis of Variance (ANOVA) is then applied to determine the parameters significantly influencing die wear. The results highlight that the billet temperature and percentage deformation are critical factors affecting die wear. The optimal process settings, which lead to minimal die wear, were validated through a confirmation experiment. Additionally, empirical models were developed to establish correlations between die wear and various forging parameters.