Firstly, material selection and pretreatment are the foundation for avoiding cracking. Cold forging has high requirements for the plasticity and uniformity of the original material, and it is necessary to select metal materials with good cold deformation ability, such as low-carbon steel, aluminum alloy, copper alloy, etc. At the same time, the surface of the material should be free of cracks, inclusions, oxidation skin, and other defects, and appropriate annealing treatment should be carried out to eliminate internal stress, improve the microstructure, and enhance its plasticity and toughness.

　　Secondly, mold design is crucial for preventing material cracking. The mold cavity should be designed with reasonable transition radii to reduce stress concentration; the gap between the punch and die should be uniform and appropriate to ensure smooth metal flow; at the same time, the lubrication conditions must also be good to reduce friction and avoid material rupture due to excessive local stress. Using advanced simulation software for finite element analysis of the forming process helps optimize the mold structure, predict potential crack locations, and take preventive measures in advance.

　　Furthermore, controlling the degree and speed of deformation is also an important means to avoid material cracking. If the deformation amount is too large during the cold forging process, it is easy to exceed the material's ultimate plasticity, leading to cracking. Generally, a step-by-step forming method is adopted, that is, the forming is gradually achieved through multiple processes, with each process controlled within the deformation range allowed by the material. In addition, cold forging is usually carried out on low-speed presses, and an excessively high deformation rate may exacerbate the tendency of brittle fracture of the material, so it is necessary to reasonably select processing equipment and process parameters.

　　Finally, it is also important not to ignore the process environment and operation specifications. Maintain a dry and clean workshop environment, avoiding surface damage to workpieces and molds due to humidity or impurities; at the same time, strictly implement the process flow, regularly check the wear condition of the mold, and timely replace or repair damaged parts to ensure the stability of the production process.



In summary, to avoid material cracking in cold forging, it is necessary to take comprehensive measures from multiple aspects such as material selection, mold design, process parameter control, and production management. Only by doing scientific and reasonable work at all stages can the quality and reliability of cold forged parts be effectively improved, and cold forging technology can be more widely applied in modern manufacturing industries.