Modelling of Direct Extrusion Process and Open-Die Forging Process Analytically and Numerically

Present works aims to derive the mathematical models for direct extrusion process for different die cross-sections and open-die forging process for elliptical billet cross-section. Though, from designer and manufacturer point of view, from industry perspective in order to overcome the limitation and complication in the mathematical modelling, a numerical simulation technique has been established to exploit the possibility of commercially available FEM software. To initiate, with fundamental material properties testing such as compression and tensile tests for aluminum alloy have been simulated and validated with its experimental results. Successively, simulated direct extrusion process for optimal curved die, closed-die forging for axis-symmetry part and then validated with its experimental results. Later, derivation for mathematical models having elliptical, square and rectangular shape die for direct extrusion process and elliptical billet cross-section for open-die forging have been derived with certain assumptions. Finally, the potential of numerical simulation again has been exploited to validate the mathematical models, which have been observed to be less than 5%. The complexities involved in simulation including the detailed assumptions in mathematical modelling have been discussed in detail