Load Prediction for the Extrusion from Circular Billet to Symmetric and Asymmetric Polygons Using Linearly Converging Die Profiles

The deformation load is the most important parameter in the press design as it affects the structure and the general integrity of the final product. Therefore, every other parameter such as die shape, friction, type of process (hot or cold), and speed considered in modeling is optimized to cut back on the metal forming load. The flow of metal is largely influenced by the geometry of the die and hence the geometric shape of the tools is the main factor by which an optimum load can be evaluated. In extrusion process the strain distribution, resulting from deformation load, and other important variables that influence material structure, such as a hydrostatic stress, are strongly dependent on the geometry of the die. In the present investigation using linearly converging die profiles, the extrusion of symmetric and asymmetric polygons such as circular, square, triangular, hexagonal, heptagonal, octagonal, and L-, T-and H-, respectively sections from round billet have been numerically simulated. Mathematical equations describing the die profiles were derived, and then using MATLAB R2009b the co-ordinate of the die profiles was evaluated. A solid CAD model for the linearly converging die profile was made using Autodesk Inventor 2013 software and numerical analysis using DEFORM software for extrusion of the above sections from round billet was then performed to predict, for dry and lubricated condition, the extrusion load during deformation. It is found that the predictive loads for asymmetric shapes are found to be higher than that of the symmetric shapes. While there is no marked difference between the predictive loads for symmetric shapes that of the asymmetric shapes is significant where L-section has the highest extrusion load, followed by T-section and the H-section given the least pressure.