Radial extrusion of gear like components - Numerical analysis and experiment

Abstract

In this paper investigations of cold radial extrusion of gear-like components are presented. Focus has been placed on load requirement, metal flow during extrusion, die filling and strain distribution within the deformation zone. Two different geometries of gear-like components were considered: with straight radial, straight tapered and with straight parallel flank profile. Extrusion load exhibits three different phases: initial steep rise, gradual load development (steady extrusion state) and rapid load rise at the end of the process when corner filling takes place. Material flow is characterized by occurrence of "double barrelling" of free profile surfaces due to friction which exists at the die-material surfaces. The highest strain values were observed in the root of the teeth while in the middle part of the workpiece lower strain values appear. In numerical FE analysis DEFORM 3D, Ver. 10.2 software was employed. For the experimental investigation special tool has been designed and made. Aluminium billets were applied.