Cold-Forging Die Optimization Using Experimental and Finite Element Analysis

This study presents an integrated technological approach for improving the service life and operational stability of a P6 die used in the cold-forging production of automotive brake connectors. The work was conducted in an industrial environment characterized by high production volumes and recurrent premature die failure. A hybrid methodology combining Shainin’s dominant-variable methodology with controlled experimentation and finite element analysis (FEA) was implemented to identify and optimize the dominant process variables affecting die durability. The attack angle, chamfer length, and machine rotational speed were determined to be the primary factors influencing stress distribution and fatigue behavior. The optimized configuration (16° attack angle, 1.4 mm chamfer length, and 88 RPM) increased die service life by 416%, improving production throughput from approximately 60,000 to over 250,000 parts per cycle. Numerical simulations confirmed that the geometric redesign effectively reduced localized Von Mises stress concentrations, contributing to enhanced structural reliability. The results demonstrate that integrating empirical industrial methodologies with numerical modeling provides a practical and replicable framework for technological improvement in high-volume cold-forging operations. The proposed approach is transferable to similar tooling optimization challenges in the automotive manufacturing sector.