Analysis of forging defects for selected industrial die forging processes

•The excess of the coolant amount can cause the Rebinder effect in tools.•It is necessary to identify the causes of laps through material research.•Numerical simulations can identify problems with underfills.

The main goal of this paper is to identify defects in forgings in selected die forging processes. The major problem is the formation of underfills due to air pockets between the forging and the tool. In the literature there is no information about modeling of such defects using FEM software, therefore, attempts were made to build numerical simulations of analyzed processes. The high agreement of the numerical modeling results with the results of the macroscopic, microstructural and defectoscopic examinations confirmed the validity of the FEM modeling assumptions and justified the use of such IT tools for the analysis of industrial plastic working processes.