Experimental and Finite Element Analysis of Closed-die Combined Extrusion-forging process: Development of Socket Adopter

• Published in: Materials today : proceedings Vol. 18; pp. 3482 - 3491
• Main Authors: Charan Nayak, Kanhu, Kumar Sahoo, Susanta
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 2019
• Subjects: Extrusion-forging; finite element analysis; material flow pattern; microhardness; microhardness; material flow pattern; finite element analysis; Extrusion-forging
• ISSN: 2214-7853; 2214-7853
• DOI: 10.1016/j.matpr.2019.07.276

The combined extrusion-forging process is used for producing parts with complex geometry those take more than one step in other manufacturing processes like casting followed by machining or by assembling. In this direction, the present work emphasizes to produce four different shapes of socket adopter using closed die combined-extrusion forging method. A combined extrusion forging test rig is designed and fabricated for producing these socket adopters. All experiments are carried out using cylindrical cast aluminium billet of the diameter of 15mm. First, the finite element method is used for the simulation of the combined extrusion-forging process for different socket adopters. The four types of socket adopters from the simulation are validated by conducting the experiments. The forming loads during the combined extrusion-forging process are calculated with punch travel for these socket adopters. The material flow patterns of these parts are investigated during combined-extrusion forging process at intermediate stages of punch travel. Socket depth and extruded length of different adopters are measured at different punch travel. Microhardness at three deformed zones on the socket adopter is measured. The highly deformed zone shows high magnitude of microhardness compares to other deformed zones.