A study of barreling profile and effect of aspect ratio on material flow in lateral extrusion of gear-like forms

184-192The aim of this study is to investigate the lateral extrusion of tapered in terms of die filling and barrel formation at the front of tooth. A series of experiments has been carried out using solid lead billets with two different billet diameters and three different billet heights of each diameter. Metal flow in the tooth region is not uniform and barreling occurs due to frictional resistance between the workpiece and the die gap surface. The barrel profile is assumed as a second order polynomial and a simple empirical relationship between the tooth dimensions and the barrel profile has been given using experimental data. Bulging profile of the tooth was measured and simulated by CAD/CAM software. Load-stroke relations and die filling ratios are obtained. In addition, Microsoft Visual Basic was coded and also magnitude and the position of the maximum stresses in the die chamber were determined by using CATIA