Numerical and Experimental Analysis of the Forging and the Extrusion Process Using DEFORM-3D

Abstract

There are several obstacles that modern manufacturing sectors must overcome to create goods with desirable characteristics, such as durability, fatigue resistance, heat resistance, corrosion resistance, and cheap production costs. As an alternative to more traditional methods of production like machining or casting, the combined extrusion-forging process is used to rise to these difficulties by enhancing material qualities, increasing production rates, and decreasing waste. In the state-of-the-art metal forming technique known as combined extrusion-forging, a billet is first compressed and then pushed through an extrusion and forging die punch configuration. The frictional conditions at the workpiece/die contact, the die shape, and the percentage area reductions are the primary determinants of the metal's flow pattern. Estimating the forming load in this process is challenging due to the high number of process factors and the complexity of the analysis required. It finds widespread use in the aerospace and automobile sectors. The goal of this current study is to develop a method for estimating the forming load necessary to manufacture a collet chuck holder using this method. Both experimental and computational studies of metal flow patterns and die cavity filling have been performed. For 3D modeling, utilized Solid works, and simulation, Deform 3D software is used. Experiments have been conducted to validate the simulation's output and both the experimental and simulation analysis findings accord with one another quite well.