Abstract
This paper is to investigate the wear characteristics of a tool in a double cup extrusion process (DCEP). The main objective of this study is to examine the influence of geometrical process parameters on the tool wear characteristics in DCEP. Two major design factors include the reduction in area in backward direction (RAB) and the wall thickness ratio of extruded can (TR). In order to verify the applicability of Archard’s wear model to massive deformation such as metal forming processes, two cases of experimental observations were compared with numerical predictions. A sequential operation has been also simulated to compare the tool wear with those in a combined operation. The simulation results were summarized quantitatively in terms of wear profiles such as contact pressure, sliding distance, and wear depth. It can be concluded from the results that severe wear occurs in regions near the punch or mandrel corner and the wear depth increases as the TR increases. This trend is intensified with increase in RAB.
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