FEM modeling and comparative study of graphite lubricants in the hot forging of AISI 1045 medium carbon steel

This study investigates the performance of water-based and oil-based graphite lubricants in the hot forging of AISI 1045 medium carbon steel, aiming to enhance product quality while minimizing die wear. Utilizing Finite Element Method (FEM) simulations and experimental analysis, we examined key factors including flow lines, dimensional accuracy, forging load, and die wear. Results indicate that oil-based graphite lubricants significantly outperform water-based options, achieving a lower average error of 0.26% in dimensional accuracy compared to 0.99% for water-based lubricants. Additionally, oil-based lubricants resulted in reduced forming loads, leading to improved energy efficiency and longer die life. Microstructural analysis revealed that oil-based lubrication yielded an average grain size of 13.50 μm, 42.60% finer than the 23.52 μm observed with water-based lubricants, enhancing mechanical properties due to the Hall-Petch relationship. Furthermore, FEM simulations demonstrated that oil-based lubricants produced lower stress levels in dies, correlating with reduced wear. Overall, the findings suggest that oil-based graphite lubricants provide superior performance in hot forging applications, enhancing manufacturing efficiency and product quality. This research underscores the importance of lubricant selection in optimizing forging processes for improved cost-effectiveness and durability in production.