In this study, die-service life analysis of hexagonal trimming dies with different edge radius and cutting width was performed. The trimming dies were prepared by grinding the front face of the die due to desired cutting width and edge radius. Prepared dies were used in cold forging of steel M6x25 hexagonal bolts and service life of each die were determined in terms of number of bolts that they can produce until they experience fracture. Numerical models of trimming operation with varying cutting width were also prepared in finite element software simufact.forming to conduct stress analysis. Production trials and finite element analysis showed that service life of trimming die was significantly affected by cutting width. It was seen that die-service life increases linearly with increasing cutting width within an optimum range of 0.8 and 1.2 mm. Similarly, the die-service life improved with increasing edge radius values. Moreover, the trimming operation carried out by using hexagonal trimming die was optimized with Taguchi method by defining 5 design parameters and 3 levels for each parameter. Minimizing the peak trimming load and maximizing the peak damage value were determined as the objective functions to find the most effective design parameters. According to the Taguchi results, the cutting width and stopping distance were seen to have significant impact on peak trimming load while the edge radius was determined to be effective on the peak damage value.

在这项研究中，对具有不同边缘半径和切削宽度的六边形修边模具进行了模具使用寿命分析。由于所需的切割宽度和边缘半径，通过研磨模具的前表面来制备修边模具。准备好的模具用于钢制 M6x25 六角螺栓的冷锻，每个模具的使用寿命根据它们在发生断裂之前可以生产的螺栓数量来确定。并在有限元软件simufact.forming中建立了不同切割宽度的修边操作数值模型进行应力分析。生产试验和有限元分析表明，切边模的使用寿命受切割宽度的显着影响。可以看出，在 0.8 和 1.2 毫米的最佳范围内，模具使用寿命随着切割宽度的增加而线性增加。同样，模具使用寿命随着边缘半径值的增加而提高。此外，通过定义 5 个设计参数和每个参数的 3 个级别，使用田口方法优化了使用六边形切边模具进行的切边操作。最小化峰值修整载荷和最大化峰值损伤值被确定为寻找最有效设计参数的目标函数。根据田口的结果，切割宽度和停止距离被认为对峰值修整载荷有显着影响，而边缘半径被确定为对峰值损伤值有效。使用田口方法通过定义 5 个设计参数和每个参数的 3 个级别来优化使用六边形切边模具进行的切边操作。最小化峰值修整载荷和最大化峰值损伤值被确定为寻找最有效设计参数的目标函数。根据田口的结果，切割宽度和停止距离被认为对峰值修整载荷有显着影响，而边缘半径被确定为对峰值损伤值有效。使用田口方法通过定义 5 个设计参数和每个参数的 3 个级别来优化使用六边形切边模具进行的切边操作。最小化峰值修整载荷和最大化峰值损伤值被确定为寻找最有效设计参数的目标函数。根据田口的结果，切割宽度和停止距离被认为对峰值修整载荷有显着影响，而边缘半径被确定为对峰值损伤值有效。