An alternative design method for the double-layer combined die using autofrettage theory

Abstract. The double-layer combined die is used for its longer life in forging. Autofrettage is a well-known elastic–plastic technology that increases the durability of thick-walled cylinders. This study explores an alternative design method of the double-layer combined die using autofrettage theory. An analytical solution for the autofrettage process of the double-layer combined die is obtained based on Lamé's equation. The relationship between the autofrettage pressure and the yield radius of the die insert is obtained, and expressions of residual stresses and displacements, which are directly related to geometric parameters, material properties and internal pressure, are derived. The finite-element simulation of a specific case is performed, and good agreement between theoretical calculations and simulation results is found. Furthermore, the effects of important parameters, including the ratio of the plastic area and yield strength of the die insert and the outer diameters of the die insert and stress ring, on the autofrettage effect are investigated. Compared with the conventional combined die, the autofrettaged die can bear larger working pressure, as expected. The use of the autofrettaged die can reduce the amount of expensive material required for the die insert and the working space of the die set, which would benefit the practical forging process.