Abstract
The traditional process of forging is often determined based on experiences which require repeated testing and repairing of dies. It also involves long production cycle and high prototype cost. In recent times, the finite element approach has evolved as an effective technique for virtual process testing and simulation-based design. The aim of this study is to model and conduct FEA on metal die using SolidWorks and DEFORM-3D software packages. This would result in the enhancement of the overall process competence and efficiency at a lower production cost. In this research paper, an effort has been made to gain insight into the process variables that affects closed-die hot forging and its interaction. As sample case, metal (AISI 1045) component is considered. Commercial software (DEFORM-3D) that uses a simulation-driven approach based on the finite element method (FEM) has been implemented. The result will be useful for tool and die developers as well as work developers for optimizing the forging process and to analyse deformation in the components especially in automotive parts.
