Finite element analysis of the stresses on the cold forged core die of the rotile part

Cold forging is a plastic forming method by applying the pressing force to the workpiece under room conditions, where the form between work tool steels called die is given. Cold forging process of the workpiece takes place at room temperature, high forging forces occur. The pressure on the workpiece and die contact surface is high, die set components are required to exhibit high mechanical properties.The service life of the dies used in the production of the ball joint body with cold forging is an important factor affecting the production costs.It is possible to minimize die costs by choosing the right die material. In this study, the core die which is the most broken die component during the cold forging of the ball joint body produced in three operations was examined. Finite element analysis is applied to the die components and workpiece used in the last operation, where the most breakage is experienced and the production efficiency is the lowest.Within the scope of this study, patented names Caldie, Unimax, Formvar and Orvar2m cold and hot work tool steels were used in the die core by applying high shrink fit ratio. Die and test samples manufactured under the same conditions were tested with destructive and non-destructive testing methods.Metallographic examinations were made on samples of heat treated and non-heat treated tool steel.A relationship has been established between the results of the tests applied to the die steels and the lifetimes of the dies used in the production of ball joints.As a result of this study, which is supported by finite element analysis, material selection, heat treatment and mechanical properties were determined.It is ensured that die cost is low and production efficiency is high.