Abstract
Forging is one of the manufacturing processes, which is preferred to produce complex component due to its advantages. New process development of forging component requires through process knowledge and experience. Many a times trial-and-error methods are used to arrive at optimum forging process and initial billet dimensions. But with help of reliable computer simulation tools, now it is possible to optimize the complete forging process and billet dimensions without a single trial. This will have direct and indirect saving of time and money with much more insight about the process and possible forging defects in the same. This paper deals with die design optimization of spring saddle used in automotive industry. Existing forging process was simulated and simulation results show under filling of component cavity with larger amount of material wasted in flash. This results in increase in the rejection of components. Existing forging process also requires higher tonnage capacity which hampers life of existing dies and forging equipment. Elimination of defects without affecting the productivity was the main challenge. The changes made in the forging process and its die design was simulated, which results in elimination of defects. Iterative simulation also helped to arrive at optimized billet size, resulting in saving of 5% of input material which increased forging yield. Complete optimized forging process requires almost 6 times lesser tonnage capacity which has direct benefit on life of dies and forging equipment. These changes in forging process and die design were implemented in physical forging trials. They were found effective in eliminating the defects, saving of input material and reduction in forging load which results into direct or indirect cost benefit to the industry in the form of reduced energy consumption. Thus simulation approach helps to optimize the forging process, improve productivity and reduce energy consumption.