Process optimization for hot forging of difficult parts by computer experiments and response surface analysis

Closed die hot forging of 304L stainless steel is difficult compared to carbon and micro-alloyed steels in terms higher forming force defects. An appropriate combination design process factors including cross-section diameter, initial billet temperature, flash land thickness crucial minimize the without causing any under-filling or folding This paper aims develop an optimized closed-die for long, thin, tubular rail body components used gasoline direct injection systems. The effects on load are investigated using computer experiments containing finite element method under a full factorial array three at levels obtain main interaction effects. Linear quadratic surface response analyses performed define relation between input factors, finally, simulations validated with some limited experiments. simulation results that fit nonlinear regression model were close agreement experiments, optimal set parameters conveniently proposed industrial production.