• cold forging
• cost model

Cold forging is a manufacturing process which is growing in the last decades, for the reason that it gives competitive solutions in a global market. However, a great impact on the process cost efficiency is related to tooling costs.
The thesis is focused on the identification of tool costs in relation of the entire cold forged process.
In the first step, using web researches, the different markets in which cold forged product can be applied are analysed, due to the advantages of cold forging process, which made it suitable for the particular markets.
Afterwards, cold forging chain and tool making chain are analysed together, by means of literature researches. Furthermore, in cold forging analysis, particular attention is paid on the identification of leverages of profitability. In order to do this, a cost model is implemented. Thanks to it is possible to estimate the cost of the final cold forged product but also to identify the most important leverage of cold forged process.
At a later stage, in order to reduce costs due to tool failures and thus to machine downtime, it is perform an analysis and classification of potential tool failures. Once that failure modes are identified, in order to reduce or eliminate them, it is made a research about the potential solutions studies nowadays about tool life improvements, and they are classified in order to identify the different areas where can be researched tool life improvements.
Researches about solutions for reducing tool failures in cold forging are made in LFT, thus department researches made in collaboration with industrial partners are described and analysed. Furthermore, in order to estimate costs savings due to department researches, cost model is applied, having thus the possibility to discover tooling costs savings due to the annual production and to the single workpiece.