How do you design a precision forging process for a complex aerospace component?

Precision forging process design involves: Material selection and billet design (accounting for forging ratio, grain flow requirements), Preform sequence design (blocker, finisher progression using simulation), Die design (optimized flash design, parting line, draft angles, die life considerations), Process parameter optimization (temperature windows, strain rate control, press tonnage), Lubrication strategy (graphite-based for hot forging, proper application method), Die preheating (isothermal or near-net-shape forging), Quality requirements (grain size ASTM 5-8, mechanical properties, ultrasonic inspection), and Tool steel selection (H13 for hot, D2 for cold). Use FEM simulation (DEFORM, FORGE) to validate metal flow, filling, die stress, and microstructure evolution before tool manufacturing.