Simulation of Lateral Extrusion of Spline Form Based on the Software DEFORM-3D

Abstract

Lateral extrusion, sometimes called injection upsetting, offers a product with central boss section having complete or segmented protrusions. Collar flanges, spur gear forms, spline or taper with shaft are examples of the products of produce by lateral extrusion. The aim of this study is to investigate the lateral extrusion of gear-like spline form in terms of forming load and load die filling ratio and comparison the results with those results obtained from a commercially FEM based programme named DEFORM-3D. A series of experiment has been carried out using solid lead billets with two different billet diameters and two different billet heights. Experiments were carried out by using a hydraulic press of which capacity 150 metric tons. Load-stroke relations and die filling ratios are obtained both theoretically and experimentally. It is obviously shown that the results obtained from the DEFORM-3D could be used for simulating of the deformation process.