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Finite element (FE) method is extensively employed in solving linear and non-linear problems and widely used particularly in analyzing a forming process. It enables the analysis on internal properties such as stress effective, forming load, metal flow and deformation to be performed, in which results in an increase on the performance of forging process. Heading process which is often performed in conjunction with other cold forging process has been simulated by FE-code DEFORMTM F3 v6.0. The numerical results were analyzed to evaluate the effect of the fillet size and the friction value on the cold heading process. It was found that the heading process provided good precision and productivity as the size of fillet was increased; due to intensification of the metal flow to infuse the die cavity. On the other hand, the friction value also played an important role in governing the reaction force between workpiece and punch in the process

Effect of Corner Radius and Friction Parameters on the Optimization of the Cold Forging Die Design