SIMULATION AND EXPERIMENTAL STUDIES FOR LATERAL EXTRUSION OF SQUARE AND PENTAGONAL HEAD FROM ROUND SHAFT

Recently, in different industries a surging trend has been observed in the demand of integral parts instead of assembled parts due to their increased strength. The components from lateral extrusion process are suitable for this purpose. Variations in load and flow direction of metal are greatly affected by the extruded geometry in this process. Keeping in view the above factors as an objective, an experimental die-punch set-up for lateral extrusion is designed and the process is simulated using finite element method both for estimation of load requirement and metal flow patterns. Experimental studies have been carried out to find the extrusion load and the direction of metal flow at different die geometry, taking lead as the billet material. The predictions both in extrusion load and the deformed configuration are in good agreement with the experiment qualitatively under different geometry conditions. Progressive flow of metal at different die geometry has also been studied