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In this study, Three dimensional finite element analysis has been carried out using FEM based DEFORM TM 3D software on hot forging of spring saddle. The influence of design parameter viz. flash thickness and process parameters viz. billet temperature, die temperature and friction coefficient along with their interactions are investigated for the responses forging load and billet temperature loss during hot forging operation using Taguchi's L27 orthogonal array. Analysis of variance (ANOVA) is employed to determine significant parameters. It has been observed that optimal factor settings for each performance characteristic are different. Flash thickness and Billet temperature and interaction of flash with billet temperature are observed as the most significant parameters affecting the responses. In order to minimize two responses simultaneously, Grey Taguchi method is adopted and optimum factor levels have been reported. Optimization of the process parameters simultaneously leading to a low billet temperature loss along with a low forging load and it is also verified through a confirmation experiment for validation of these results. Confirmatory results prove the potential of Taguchi design of experiments, ANOVA analysis and Grey Taguchi method in Multi-objective optimization of process parameters.

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