Design and Analysis of Combined Extrusion Forging Die Behavior Under Thermal Structural Loads

We all know extrusion and forging are two different processes of manufacturing but in recent past researches combined these two process to reduce the production time, production cost etc.Combined extrusion-forging processes are now getting importance for its abilities to give improved material properties, high production rate and less material waste when compared with that produced by machining, casting or by assembling the individual parts produced by different manufacturing processes. In its simplest form of combined extrusion forging process, a billet is forged by punch and dies with punch/die or both containing an opening for extrusion. This tooling arrangement permits the simultaneous lateral spread due to forging, and backward/forward extrusion or both forward and backward extrusion simultaneously through the die/punch opening(s). In this study we are going to develop a die for extrusion-forging using knowledge from previous journals and books, we will develop a die for a flange with pipe using CAD and CAE packages. A basic die is designed and tested at maximum working conditions under thermal structural loads in simulation software ANSYS and the design of the die is further improvised to minimize the stress and improve life based on safety factor issues