Thermal Management in Multi-Stage Hot Forging: Computational Advances in Contact and Spray-Cooling Modelling

Innovative approaches in hot forging, such as the use of floating dies, which aim to minimise burr formation by controlling material flow, require precise management of die geometry distortions. These distortions, primarily caused by thermal gradients, must be tightly controlled to prevent malfunctions during production. This study introduces a comprehensive thermal analysis framework that captures the complete forging cycle-from billet transfer and die closure to forging, spray-cooling, and lubrication. Two advanced heat transfer models were developed: a pressure- and lubrication-dependent contact heat transfer model and a spray-cooling model that simulates fluid dispersion over die surfaces. These models were implemented within the finite element software FORGE-NxT to evaluate the thermal behaviour of dies under realistic operating conditions. These two new models, contact and spray-cooling, implemented within a full-cycle thermal simulation and validated with industrial thermal imaging data, represent a novel contribution. The simulation results showed an average temperature deviation of just 5.8%, demonstrating the predictive reliability of this approach. This validated framework enables accurate estimation of thermal fields in the dies, and offers a practical tool for optimising process parameters, reducing burr formation, and extending die life. Moreover, its structure and methodology can be adapted to various hot forging applications where thermal control is critical to ensuring part quality and process efficiency.