Finite Element Analysis And Optimization Of Hot Forging Die Based On Wear

Hot forging die is important forgings production equipment, service life of hot forging die not only affect product quality, is also directly related to productivity and cost. Statistics show that failures due to wear of hot forging die accounted for 70% of the total number of failures. Therefore it is necessary to predict die wear and explore the effect of different parameters on wear and optimize parameters.Based on modified Archard wear model using finite element simulation software DEFORM and aimed at forging a differential cover to analyzes the process parameters (billet and the mold temperature, forming speed), structural parameters (die thickness of edge, the fillet radius) and mold material physical properties (thermal conductivity, specific heat capacity) on the effect of forging die wear.For an automotive connecting rod mold, wear prediction is proceed based on Archard tempering parameters model. Compared the measured contour lines and predicted wear contour lines to obtain the wear coefficient K and adjustment coefficients a. In addition, three Archard wear models (basic Archard model, modified Archard wear model, Archard tempering parameter model) were compared. It showed Archard tempering parameter model was the highest accuracy for forecasting wear.According to the people-controllable parameters, using the Taguchi method, different parameters of automobile connecting rod mold were simulated with DEFORM-3D simulation software. The optimal combination of the parameters:Die preheating temperature is 200℃, the forming speed is 200mm/s, die thickness of edge is 4.5mm, the fillet radius is 4mm. And simulations were performed to verify under the optimal parameters. Results showed that the single highest wear from original molds 5.52×10-5mm down to 4.49×10-5mm, maximum wear down 18.66%. It was conducive to reduce wear and improves die life using the parameters combination.