ABSTRACT:

The present work focuses on the design and analysis of a closed die for forging an automotive crankshaft component. Forging is a preferred manufacturing process for such components due to its superior mechanical properties, high reliability, and material efficiency. Traditionally, die design relied heavily on trial-and-error methods, leading to high costs and longer development cycles. In this study, a systematic approach was adopted using CAD/CAE tools and finite element simulations to optimize the die design. Blocker and finisher dies were modeled and meshed, followed by iterative simulations using Forge Nxt software to analyze metal flow, under-filling, fold formation, force requirements, stress distribution, and die wear. A total of seven iterations were carried out to eliminate forging defects, after which the final die design was validated for stress and force limits within a 5000T press capacity. Die wear analysis indicated minimal high-wear zones, ensuring longer service life. A forging shop trial confirmed that the manufactured crankshaft dimensions were within the acceptable tolerance of ±1.5 mm. The results highlight that the integration of simulation in die design significantly reduces development time, material wastage, and trial costs while improving product quality and reliability. This study demonstrates the effectiveness of computer-aided die design in achieving defect-free forgings and meeting industrial requirements for precision, performance, and cost-effectiveness in automotive component manufacturing.