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TECHNICAL PAPERS

Analysis of Cold Extrusion of Non Re-entry Product Shapes

[+] Author and Article Information
Santosh Kumar, Kripa Shanker, G. K. Lal

Indian Institute of Technology, Kanpur, India

J. Manuf. Sci. Eng 124(1), 71-78 (Feb 01, 2001) (8 pages) doi:10.1115/1.1413777 History: Received September 01, 1998; Revised February 01, 2001
Copyright © 2002 by ASME
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References

Yang,  D. Y., and Lee,  C. H., 1978, “Analysis of 3D Extrusion of Sections Through Curved Dies by Conformal Transformation,” Int. J. Mech. Sci., 20, pp. 541–552.
Yang,  D. Y., Kim,  M. V., and Lee,  C. H., 1978, “An Analysis for Extrusion of Helical Shapes from Round Billet,” Int. J. Mech. Sci., 20, pp. 695–705.
Yang,  D. Y., Han,  C. H., and Lee,  B. C., 1985, “The Use of Generalized Deformation Boundaries for the Analysis of Axisymmetric Extrusion Through Curved Dies,” Int. J. Mech. Sci., 27, pp. 653–664.
Yang,  D. Y., Han,  C. H., and Kiuchi,  M., 1986, “A New Formulation for Three Extrusion and its Application to Extrusion of Clover Sections,” Int. J. Mech. Sci., 28, pp. 201–218.
Yang,  D. Y., Lee,  C. M., and Cho,  J. R., 1990, “Analysis of Axisymmetric Extrusion of Rods by the Method of Weighted Residuals Using Body-Fitted Coordinate Transformation,” Int. J. Mech. Sci., 32, pp. 101–114.
Gatto,  F., and Giarda,  A., 1981, “The Characteristics of the Three Dimensional Analysis of Plastic Deformation According to the SEER Method,” Int. J. Mech. Sci., 23, pp. 129–148.
Kiuchi, M., Kishi, H., and Ishikawa, M, 1981, “Study on Non-Symmetric Extrusion and Drawing,” Proceedings of 22nd International Machine Tool Design Research Conference, pp. 523–532.
Gunasekera,  J. S., and Hoshino,  S., 1985, “Analysis of Extrusion of Polygonal Sections Through Stream-lined Dies,” ASME J. Eng. Ind., 107, pp. 229–232.
Boer,  C. R., and Webster,  W. D., 1985, “Direct Upper Bound Solution and Finite Element Approach to Round to Square Drawing,” ASME J. Eng. Ind., 92, pp. 158–162.
Han,  C. H., and Yang,  D. Y., 1986, “A New Formulation for 3D Extrusion and its Application to Extrusion of Clover Sections,” Int. J. Mech. Sci., 28, pp. 201–218.
Lee,  C. M., Yang,  D. Y., and Kim,  M. U., 1990, “Numerical Analysis of Three Dimensional Extrusion of Arbitrarily Shaped Sections by the Method of Weighted Residuals,” Int. J. Mech. Sci., 32, pp. 65–82.
Shim,  Hyun-Woo, Kim,  Dong-Won, and Kim,  Naksoo, 1993, “A Simplified 3D Finite Element Analysis of the Non Axisymmetric Extrusion Process,” J. Mater. Process Technol., 38, pp. 567–587.
Reddy,  N. V., Dixit,  P. M., and Lal,  G. K., 1995, “Die Design for Axisymmetric Extrusion,” J. Mater. Process. Technol., 55, pp. 331–339.
Kumar,  Santosh, Shanker,  Kripa, and Lal,  G. K., 1999, “A Feature Recognition Methodology for Extrudable Product Shapes,” Int. J. Prod. Res., 37, No. 11, pp. 2519–2544.
Kumar, Santosh, Shanker, Kripa, and Lal, G. K., 1998, “Feature Based Modelling of Cold Extrusion Process,” Proceedings of the Third Japan-India Joint Seminar on Advanced Manufacturing (Oct. 20–24, 1998), University of Tokyo, Tokyo (Japan), pp. 130–137.
Prager, W., and Hodge, P. H. Jr., 1951, Theory of Perfectly Plastic Solids, John Wiley (USA).
Chang, K. T., and Choi, J. C., 1971, “Upper Bound Solutions to Extrusion Problems Through Curved Dies,” Proc. 12th Midwestern Mechanics Conference, Univ. Notre Dame (USA), 382.
William, H. P., Saul, A. T., William, T. V., and Brain, P. F., 1996, Numerical Recipes in C: The Art of Scientific Computing, Cambridge University Press (UK).
Arora, J. S., 1989, Introduction to Optimum Design, McGraw-Hill (USA).

Figures

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Extrudable shapes (a) non re-entry (b) re-entry
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Deformation zone and typical stream surfaces in extrusion
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Geometry of die and streamlines in an extrusion die
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Construction of power elements for a general non re-entry extrudable shape
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Relationship between die surface and projected surface for frictional power calculations
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Comparision of extrusion pressure evaluated for circular section with experimental results of Yang et al. (1990)
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Variation of total power and its constituents with die length for 3rd order polynomial die
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Examples for validation of the model (a) rounded square (b) ellipse (c) clover and (d) trocoidal sections
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Variation of extrusion stress at different reductions (example Fig. 8) using a 3rd order polynomial die
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Variation of relative extrusion stress with friction and die length at 80% reduction
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Variation of relative extrusion stress with friction at different reductions

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