Simulation-based analysis of load and stress in 42CrMo4 gear blank and H13 die for improved forging performance

42CrMo4 is a versatile alloy steel finds it’s applications in forged automotive components. This paper investigates the effective load analysis of the 42CrMo4 alloy steel during forging. The final component is prepared via hot forging. Mechanical properties are evaluated using tensile testing machine and impact properties are evaluated using Impact testing machine. Hardness of the material is measured by using Rockwell Hardness tester. The microstructure is observed using Scanning Electron Microscope. The load prediction, effective strain, effective strain rate, effective stress was calculated by using deform software. The novelty of this paper presents the effective load the material 42CrMo4 can hold safely without failure or damage. Deform software simulations for 42CrMo4 steel identified safe limits of 6.52 × 10⁷ N load, 4.46 strain, 2680 (mm/mm)/s strain rate, and 1810 MPa stress, ensuring reduced risk of failure.