Experimental investigation and 3d analysis of combined extrusion-forging process

Abstract

Combined extrusion-forging is a metal forming process where the billet is forced through the extrusion and forging dies to get the required product. Combined extrusion-forging processes are now getting importance because of improved mechanical properties, less capital cost, high production rate and less material waste when compared to conventional manufacturing processes like casting and machining. Combined extrusion-forging is used in the manufacturing of a wide range of engineering components. Due to the complexity of the forming process and because of so many process variables, it is difficult to predict the forming load required to manufacture a given component. The present research work emphasizes on the estimation of forming force for combined extrusion-forging process of Collet chuck holder. Experimental studies are carried out to compare the results obtained from the Finite element analysis simulation. Experiments are performed for Collet chuck holder using aluminum billet using required die sets in ambient temperature. Metal flow patterns and filling of die cavities has been studied in the experimental analysis. The modelling has been done by using 3D modelling software Solid works and simulation through the finite element analysis. The results obtained from the simulation results are in good agreement with the experimental results.