Die wear analysis and pre-forging process optimization of hot forging for automobile flange fork

The purpose of this study is to better understand the wear mechanisms of hot forging die, and to propose a high-temperature wear model to predict wear condition of hot forging die more accurately. The wear mechanisms of 5CrMnMo steel at high temperature were investigated with the pin-on-disk wear tests. The results demonstrate that three competing wear mechanisms exist on the worn surface, which are respectively adhesive wear, abrasive wear, and oxidation wear. A modified Archard wear model considering high-temperature wear was proposed. By comparing the simulation results with the experimental wear depth, it shows that the new wear model can accurately predict the wear of 5CrMnMo steel in the high-temperature pin-on-disk wear tests. Based on the proposed high-temperature wear model, taking the forging process of the automobile flange fork as an example, the response surface method (RSM) is applied to optimize the geometric parameters of the preform die of the flange fork to reduce die wear and extend die life. This study will be beneficial to the accurate prediction of die wear and the optimization design of die geometry in hot forging process.