Enhancing tool longevity through TiN coating in multistage cold forging: implementation and analysis using Archard’s wear theory and FEA

Abstract

Multistage cold forging is widely used in manufacturing; however, high punch wear limits tool life, increasing operational costs and downtime. This study examines the effect of Titanium Nitride (TiN) coating on punch life in multistage cold forging using Archard’s wear theory and Finite Element Analysis (FEA). The research addresses challenges related to tool wear and premature failure, which impact production efficiency, by comparing the punch life of uncoated and TiN-coated punches under identical forging conditions. Archard’s wear theory describes the progressive wear behavior of TiN-coated punches, while FEA simulations with Simufact Forging provide detailed visualizations of stress distributions, wear hotspots, and failure mechanisms. The results show a significant improvement in punch life with TiN-coated punches, where the uncoated punch lasted 9,520 strokes, and the TiN-coated punch lasted 18,051 strokes, representing an increase of approximately 89.6%. Further FEA analysis corroborated these findings, predicting 9,622 strokes for the uncoated punch and 19,496 strokes for the TiN-coated punch.These findings confirm that TiN coatings effectively enhance tool durability, reduce wear, and optimize cold forging processes, thereby reducing operational costs and improving overall efficiency. © The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2025.