Abstract

Abstract For an economic production with a high process reliability, an increased tool life is required. Therefore, the necessity exists to give a reliable estimation of the tool life during the design of new tool systems. Especially for cold forging processes, the failure caused by surface fatigue is characteristic. Different approaches are suitable to calculate the time period until the initiation of fatigue cracks. The aim of this paper is to assess the applicability of different failure concepts for a closed cold forging die. The critical, process-dependent load is quantified and localized by using a finite element method. Based on the resulting stress–strain distributions, the damage parameters are calculated yielding different estimates of tool life that are compared with practically experienced data.

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