APPLICATION OF COMPUTER SIMULATION TO OPTIMIZE PARAMETERS IN HOT FORGING PROCESS FOR SOLVING PROBLEMS IN THE PRODUCTION OF AUTOMOTIVE COMPONENTS

This research aims to study the wear behavior that occurs with hot forging dies caused by the influence of the work piece’s temperature, the die’s temperature, and the coefficient of friction. The material of the die used in this study was steel with JIS standards and SKD61 Grade. The material of the workpiece was 5CM435 Grade. The default size of the workpiece and production factors were calculated and analyzed by using the Finite Element Method. The study was started by simulating workpiece forging at 850 degrees Celsius, 950 degrees Celsius, 1000 degrees Celsius, 1150 degrees Celsius, and 1250 degrees Celsius for analyzing the workpiece’s flow and wear behavior of the die’s surface under forging pressure of 400 tons with a die temperature from 120 degrees Celsius to 180 degrees Celsius. The results of the analysis revealed that the die’s temperature at 692.41 degrees Celsius and the workpiece’s temperature at 1,250 degrees Celsius yielded the most absolute workpiece flow. The absolute default size of a cylindrical workpiece had a diameter of 13 millimeters with a length of 155 millimeters and the workpiece’s temperature was set at 850 degrees Celsius. Abrasive wear occurred with the die’s lower surface at the highest level. At 1,000 degrees Celsius, plastic deformation occurred at the die’s lower surface. Stress occurred when the workpiece was in the scope of the graph on fracture criteria. From computer simulation forging, It indicated that appropriate adjustment of variables helped to reduce plastic deformation and mechanical fatigue.