This study aims at exploring the multi-pass forging of Torx Round Flange Bolt (automotive fastener) to simulate each pass forging process using FEM simulation. The software is used to carry out the simulation analysis. Constant shear friction is always assumed at the interface between die and workpiece to explore the effective stress, the effective strain, the velocity filed, and the forging force for each pass. Through the pass schedule plan and design based on FEM analysis, the four-pass forging process is designed to form the Torx Round Flange Bolt compared the five-pass forging. It is noted that the total forging force is 1,204 kN, so the 200 tons machinery in the factory can be chosen to manufacture this automotive fastener. The die stress analysis for each pass has been explored to realize whether the dies are damaged or not. The forming feasibility of Torx Round Flange Bolt can be performed by FEM simulation. All dies designs and forming results can be proposed to the dies manufacture so as to perform the realistic experiments. Comparisons between FEM and experiment for final product dimensions can be carried out. The maximum dimension error is just around 3.32% to show a good agreement with the experiment. The research results can provide to the industries as the references of establishment of multi-pass forging technology.

这项研究旨在探索Torx圆法兰螺栓（汽车紧固件）的多道次锻造，以使用FEM模拟来模拟每个道次的锻造过程。该软件用于进行仿真分析。在模具和工件之间的界面处始终假定恒定的剪切摩擦力，以探索每次通过的有效应力，有效应变，速度场和锻造力。通过基于FEM分析的通过计划和计划，设计了四遍锻造工艺，与五遍锻造相比，形成了Torx圆法兰螺栓。值得注意的是，总锻造力为1,204 kN，因此可以选择工厂中的200吨机械来制造这种汽车紧固件。已经探索了每次通过的模具应力分析，以了解模具是否损坏。梅花圆法兰螺栓的成形可行性可以通过有限元模拟来实现。可以将所有模具设计和成型结果建议给模具制造，以进行实际的实验。FEM和最终产品尺寸的实验可以进行比较。最大尺寸误差约为3.32％，与实验显示出良好的一致性。研究成果可为工业界建立多道次锻造技术提供参考。32％的人表示与实验相符。研究成果可为工业界建立多道次锻造技术提供参考。32％的人表示与实验相符。研究成果可为工业界建立多道次锻造技术提供参考。