August 2025 Volume 7

MAINTENANCE

a forged aluminum piston, a traditional single-step analysis predicted only moderate stress levels. A tightly-coupled simulation was required to reveal the extreme tensile stresses that occurred midway through the forging stroke—not at the maximum load— which led to the real-world die failure.

redesign saved one manufacturer more than $35,000 in tooling costs by eliminating fractures. Another operation multiplied die life by more than 30 times through simple design improvements informed by simulation. Forging companies that embrace predictive analysis and continuous improvement gain a competitive edge. By investing upfront in engineering, they reduce downtime, improve product consistency, and ensure safer operating conditions on the shop floor. The Path Forward: Proactive Engineering Die failure is a fact of life in forging—but it doesn’t have to be an unpredictable or costly one. With the right tools and engineering approach, companies can identify risks, implement smarter designs, and achieve dramatic improvements in die performance and reliability. As the forging industry moves forward, the best performers will be those who treat die life as a controllable variable, not a fixed cost. Simulation, data analysis, and design innovation are essential tools for any company serious about performance, safety, and profitability in today’s forging landscape. Credits: This article is based on content developed by Scientific Forming Technologies Corporation in partnership with SCRA Applied R&D and industry collaborators, as part of the PRO-FAST program, sponsored by the Defense Supply Center Philadelphia and Defense Logistics Agency – Research and Development. It's now quick & easy to donate to the Forging Foundation. Just go to www.fierf.org and click on the "Donate" tab. Make your donation today!

Figure 3: Punch simulation (left) show the extreme tensile stresses in red, which led to die failure The forged aluminum piston (right) is also shown.

Combatting Die Wear Not all failures are dramatic. Die wear is a slow killer that can be just as costly. In one hot-forged spindle process, wear in the second station reduced die life significantly. Engineers used the Archard wear model to simulate wear patterns and test alternate preform designs. A redesigned round preform reduced metal sliding and minimized punch wear in the final operation, all without sacrificing productivity. Practical Solutions: What Companies Can Do Based on decades of industry experience and case studies, the following strategies are recommended to prevent die failure: • Reduce forming loads: Adjust the process or part design to minimize peak stresses. • Enhance material strength: Use higher-grade die steels or heat treatments to increase resilience. • Redesign dies for strength: Improve geometry to distribute stress more evenly. • Support the die properly: Add lateral or radial support to mitigate bending stress and improve stability. • Control the process: Ensure proper lubrication, thermal management, and alignment to prevent unforeseen loads or misalignment during forging. Companies should also incorporate root cause failure analysis into their standard practice. By identifying where and why a failure occurred, teams can engineer solutions that prevent recurring issues. The Business Case for Prevention Engineering away die failure is as much about technical optimization as it is about protecting the business. A single die

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