The die failure prediction and prevention of the orbital forging process

The die failure occurs if the stress is too large. In this paper, the die stress analysis of the orbital forging process had been carried out to obtain the die stress distributions and predict the die failure. The different installation positions of punch, preforms, and profiles of punch tip and tool configurations were proposed to find the die failure conditions. The results of this study showed the installation error, punch tip with long mandrel and split die configuration had resulted in significant die stress and die failure occurred. The new punch profile and preform shapes had been designed to prevent the die failure and product defects. FEM code had been adopted to simulate the forging process and analyze the die stress. The upsetting tests had been carried out to obtain the flow stress parameters of AISI 4115. A PXW-200 orbital forging press had been adopted for the orbital forging tests. The failures of punch were observed in the experimental tests and precisely predicted by the simulation.