Die performance and its service life are a non-trivial issue in metal-forming industry due to three overriding issues in this industry cluster: productivity, cost and quality are mainly dependent on it. Many factors in die life cycle from design and fabrication to downstream service all affect die performance and its service life. These factors could include die design and structure, material properties, dies manufacturing and metal-forming processes, and die service conditions. The issue about how to develop an efficient and practical methodology for die life assessment and improvement has not yet been fully addressed despite the fact that dies have been used in industry for many decades. In this paper, the metal fatigue theory and FEM technique are used as the basis for the development of a methodology for die fatigue life analysis and improvement. The stress-life or S-N approach is used for die fatigue analysis. To explore extensively and reveal the dynamic die stress state panorama during the forming loading cycle, a CAE-based approach is deployed for stress analysis. Based on the S-N approach and CAE analysis, a CAE-enabled methodology is then orchestrated and finally implemented in this research. Using an industrial part as a case study, the validity, robustness and efficiency of the developed methodology are verified. The methodology can provide a satisfactory solution for die life assessment and improvement in metal-forming industry.
- CAE-enabled methodology
- Die design
- Fatigue life analysis
ASJC Scopus subject areas
- Strategy and Management
- Management Science and Operations Research
- Industrial and Manufacturing Engineering