Design & optimization of life of hot forging die

In this research paper we are studying on optimizing the life of hot forging die. The process of improving the life of the hot forging die we are doing changes in the die design as per the stresses induced in the dies. The stub axle is used as a test model for experimenting. The design of stub axle using designing software named as CREO for the simulation and design the upper and lower dies. In this (AISI H13) tool steel material is used as die material and 3% nickel steel and alloy steel is used as stub axel material. To improve the life of the die the sharp corner of the dies converted into the fillet and the edges into the radii and also „Draft Angle‟ are added to the top & bottom die cavity. Then software are used to perform the various (FE) analysis processes on the designed dies using the „ANSYS‟ Software. In ANSYS „directional deformation‟ analysis are performed on both the upper and lower dies respectively and the „Equivalent Stress‟is analyzed. The experimental results showed the stresses are reduced after applying the radii and „Draft Angle‟ on the dies by applying various gradually increasing force on the dies. In „Static Structural Analysis‟ are calculate the „FACTOR OF SAFETY‟ and applied the gradually increasing force on the dies for the „Total deformation‟. After calculating the various factors related with the forging process. Which resulted decreasing in effective plastic strain and overall distribution of effective stress during the die contact are reduced. Hence tends to optimize some amount of the hot forging die life.