Wear analysis of solid state forging for high-strength ball head hanging ring

Abstract In the process of die service, mold wear failure is the most common failure form. This paper analyzes the mold wear during the solid-state forging process of a certain high-strength aluminum alloy ball head hanging ring. Based on Archard’s wear theory, finite element analysis software was used to determine the influence of main process parameters on mold wear through orthogonal tests. Among these parameters, the forging temperature had the greatest impact on mold wear, while the forging speed and mold temperature had lesser impacts. The optimal process parameters for the solid-state forging process were determined to be a die forging temperature of 540°C, a mold temperature of 150°C, and a die forging speed of 300 mm/s.