Accurate modelling of the process forming chain to predict cold forged component geometry

Being in an industrial contest time a key parameter, very often the design of new forging sequences through numerical simulation leads to simplified models which do not allow a correct evaluation of both process and geometric parameters. In the present work, the multi-step cold forging of a small axi-symmetric automotive component, taken as reference case, is investigated. The Authors compare the results obtained by simulating the whole process chain for the component manufacturing with the ones obtained by a more simple numerical model. It turns out how critical it is in terms of results reliability not only the validation of input data but also the correct modelling of the whole process chain.