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Die wear, which is defined as a surface damage or removal of material from one or both of two solid surfaces in a sliding, rolling or impact motion relative to one another, is considered the main cause of tool failure. Wear is responsible for 70% of tool failure and a potential source of high costs; as much as 30% per forging unit in the forging industries [1]. This paper presents a unique wear prediction and measurement method for open die forging using a modified Archard equation, 3D FE simulation (to represent the actual forging process precisely) and an industrial scale forging trial. The proposed tool and experimental design is aimed at facilitating a cost effective method of tool wear analysis and to establish a repeatable method of measurement. It creates a platform to test different type of lubricants and coatings on industrial scale environment. The forging trial was carried out using 2100T Schuler Screw press. A full factorial experiment design was used on 3D simulation to identify the process s...

Defining a method of evaluating die life performance by using finite element models (FEM) and a practical open die hot forging method