Three Dimensional Analysis of Combined Extrusion-forging Process

Abstract

Combined extrusion-forging processes are very importance due to some good abilities such as improved material properties, high production rate and less material waste compared to other manufacturing processes such as machining, casting or assembling of different parts. In simple form working principle of combined extrusion-forging process is described as a billet or workpiece is first forged by primary die i.e. punch and then with punch/die or both containing an opening for extrusion.
Such type of arrangement allows the simultaneous lateral spread due to forging, and backward/forward extrusion or both forward and backward extrusion simultaneously through the die/punch opening. The metal flow pattern is dependent on a number of factors, including the frictional conditions at the work piece/tooling interface ,the geometry of the dies; particularly the size of the dies hole; the material type; and the percentage area reductions In such field, the present work emphasizes on estimation of strain distribution using Von Mises, effective strain distribution, total displacement of material in all the directions and plot the graph for prediction of central burst during extrusion process. These all distributions are found out by using finite elemental analysis through DEFORM-3D software. This is carried out on square shaped socket adopter. In simulation analysis the effect of temperature is assumed as constant and ambient temperature is taken.
Theoretical or mathematical modelling is also carried out to find out the velocity and strain of different regions using upper bound analysis. In upper bound analysis kinematic admissible velocity distribution is applied for velocity.