Modeling of a Metal Luggage Handle with the Finite Volume Method and Factorial Experimental Design

Abstract

This research aims to investigate the influence of process parameters during hot forming of SCM 435 material using SKD61 steel molds on both product quality and mold wear. The study employs simulation techniques combined with factorial experimental design (DOE). The modeling process uses Simufact Forming software to obtain test results and predict forming outcomes by creating a finite volume mold model. The model includes 24 base runs, with each run replicated twice/one experimental design, resulting in 48 total case-studied experiments.
The findings reveal that the optimal parameters for hot metal forming involve a workpiece diameter of 13 mm and a length of 155 mm, with the following optimal conditions: workpiece temperature of 1,250 ℃, mold temperature of 120 ℃, and mold friction of 0.3. These conditions result in a formed volume of 12,828 cm³ and a hammering force of 104 kN-m. The overall desirability score was found to be 96.96 percent.