Optimization of tool study is one of the important aspects in forging to estimate life cycle of the die in production criteria to increase production rate. In some occasion’s tool material may crack or break due to non-uniform loading conditions acts on the surface area of bottom die. Complex closed die forging must have to optimise in more ways to get ultimate production rate without failure of tool. Present paper discusses the damages in critical areas by analysing the bottom die using Ansys software to note the stress areas on the bottom die. The paper further discuss practical possibility if crack propagated and damaged microstructures for better clarification about the die making materials. The practical approach study gives good optimal life study of the materials used in forging techniques. The process carried out on 1 ton hammer loads for lug die as a case study.
