Tools in hot forging processes undergo high thermal and mechanical loads and thus experience corresponding fatigues. Mechanical fatigue can be reduced by design optimization, but process related changes are needed in order to minimize the thermal fatigue. Especially the control of the ground temperature is important since it influences a large number of tool attributes e.g. strength and ductility, peak temperature and temperature difference. The use of an active cooling system allows a targeted control of the tool ground temperature thus leading to a reduction in process interruptions as well as maintenance time. In comparison to common straight drilled cooling channels, tool-specific cooling systems are known to remarkably take influence on an individual tool design, thus improving tool durability. The current study deals with the numerical investigation of a forging die with an oil based integrated cooling system. Different parameters like the coolant temperature and the mass flow rate were considered in order to evaluate the behaviour of the system during application. The results were compared with the temperature distribution in the forging die without integrated cooling. The findings of this work will help to further optimize the hot forging die and in return lead to more efficient forging processes.Keywords: Cooling system, design optimization, forging, thermal effects, numerical study, FEM
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