RESEARCH PAPER
Improving process reliability and dimensional accuracy in precision forgings: a comparative study of cold and hot trimming for the automotive industry
1
Wroclaw University of Science and Technology, Department of Metal Forming, Welding and Metrology, Poland
Submission date: 2025-05-22
Final revision date: 2025-08-20
Acceptance date: 2025-11-16
Online publication date: 2025-12-15
Publication date: 2025-12-15
Corresponding author
Łukasz Dudkiewicz
Wroclaw University of Science and Technology, Department of Metal Forming, Welding and Metrology, Poland
Wroclaw University of Science and Technology, Department of Metal Forming, Welding and Metrology, Poland
Eksploatacja i Niezawodność – Maintenance and Reliability 2026;28(2):214294
HIGHLIGHTS
- Comprehensive analysis of the precision cold and hot trimming process.
- Analysis of the impact of the trimming method on overall process reliability.
- Macroanalysis combined with 3D scanning.
- Numerical modeling of the forging and trimming process.
- Operational durability of cold trimming and hot trimming tools.
KEYWORDS
tool wearmaterials engineeringprocess reliabilityprecision hot forgingtool durabilityperformance tracking
TOPICS
ABSTRACT
The article presents research on the analysis of the possibility of modifying the hot die forging process by replacing cold trimming with hot trimming. The study examines the effect of this modification on the precision forgings and the improvement of process efficiency and reliability. The research focuses particularly on the impact of the trimming method on overall process reliability, understood as the stability, repeatability, and robustness of the forging operation in industrial conditions. The components are made of austenitic stainless steel and manufactured using a hammer and trimmed using an eccentric press with a pressing force of 105 tons. The research results enabled the selection of the optimal solution for flash trimming—whether cold or hot—taking into account tool durability, the elimination of production bottlenecks and the achievement of high dimensional and shape accuracy of the forgings themselves. The conducted studies confirmed the usefulness and reliability of numerical modelling results for the analysis of one of the forging and trimming.
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