A THEORETICAL AND EXPERIMENTAL STUDY FOR THE LOAD OPTIMIZATION OF GEAR-LIKE PROFILES BY USING FORWARD AND LATERAL EXTRUSION

Abstract

The main purpose of this research is to investigate the minimum deformation load by selecting a suitable forming method for manufacturing of gear-like sections and to compare the load estimation methods between Upper Bound Analysis and DEFORM-3D. Forward and lateral extrusion were chosen as two different forming methods. The effect of die transition geometry on deformation load was also investigated by straight tapered and cosine profiles. A newly kinematical admissible velocity field to analyze different profiles of extrusion dies was proposed by upper bound analysis. Al 1070 was used as working material. Experiments using five sets of dies with gear-like form were performed, and the measured forming load results were compared with the predictions of the theoretical solutions. Experiments were carried out on the 150 metric ton hydraulic press.