Due to relatively high cost of the tooling in closed die forging the increasing of tool life is vitally important. The dies can failure due to cracks caused by overloading, low cycle fatigue or abrasive wear. On the other hand, the die deflection can cause deterioration of the forged part shape. The paper presents the ways for increasing of tool life and product accuracy by means of implementation of simulation. It can be done by modification of die design that reduces stress concentration in fillets or by using assembly dies that have splits in critical areas in combination with shrink rings and inserts. Finite element simulation allows to analyze the effectiveness of different variants of die design and to select the most effective ones in terms of tooling cost. Simulation also generates profiled shape of the die that compensates elastic deformation of tooling set and provides precise geometrical accuracy of a forged part.

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