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This chapter discusses the factors involved in the design of impression-die forging systems. It begins by presenting a flow chart illustrating the basic steps in the forging design process and a block diagram that shows how key forging variables are related. It then describes the requirements of various forging alloys, the influence of machine operating parameters, and production challenges related to lot tolerances and shape complexity. The chapter also covers the design of finisher dies, the prediction of forging stresses and loads, and the design of preform dies for steel, aluminum, and titanium alloys.

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