Optimization of Forging Folding Defects Based on Finite Element Simulation and Experiments

To address the issue of folding defects in the forging process of automotive brake levers, this paper established a forging simulation model based on the finite element method. Through simulation analysis, the regions prone to folding were identified, and the correlation between abnormal material flow and mold parameters was further revealed using mesh deformation tracking technology. Subsequently, the optimal parameter combination for the forging process was obtained through orthogonal experiments, and the influence order and significance level of each parameter on folding defects were determined through range and variance analysis. Finally, the validity of the optimization was verified through actual production experiments, along with observations of metal flow lines and metallographic structures. The results indicate that the velocity and direction of material flow contribute to the formation of folding defects. After optimization, the velocity difference was reduced to 2.5, while strain and stress were decreased by 31.37% and 31.02%, respectively. Ultimately, the folding defect issue was successfully resolved through the proposed optimization approach.