Improving the Fatigue Resistance Of Cold Forging Tools by Fe Simulation and Computer Aided Die Shape Optimization

Abstract
It is the intention of the present article to point out a new method for computer aided tool optimization as part of computer integrated tool manufacturing. Based on the results of finite element (FE) analysis and subsequent tool failure simulation, it is possible to optimize the FE model of a tool already at the stage of construction, in order to enhance the service life and process reliability. The permissible degree of freedom for any shape correction, of course, is mainly limited by constructive constraints of the tool and the properties of the material flow during the extrusion process. Thus the resulting optimized geometry has to he considered as a possible constructive alternative. However, analytical as well as practical solutions already show that a parabolical or elliptical curved surface contour, replacing a regular radius, not only improves the fatigue resistance but may have a positive influence on material flow behaviour, friction forces and resulting tool loads as well (1). The influence imposed on the material flow by the geometrical modification of the die shape will be clarified in future by the results of FE process simulation. A renewed simulation run, employing the optimized shape, may be conducted immediately after the optimization process. Along with current material research, the simulation of tool failure based on the finite element method (FEM) analysis of forging techniques (FE process simulation) therefore represents a promising direction for future developments (2–4).

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