Combined Extrusion-Forging: Simulation, Experimental and Microscopic Investigation of Axisymmetric Single Collar Collet Chuck Holder

Abstract

Combined Extrusion-Forging process is a renowned metal forming method which serves as a pathway for manufacturing components of complex design. In that context processing a component with better mechanical and metallurgical properties can be enhanced by severe plastic deformation which processes the fine-grained materials formation in the product. These fine-grained materials achieved by SPD makes the component with superior quality. The novelty of the concept is to validate the presence of fine-grained materials at lower ram displacement. This paper presents the estimated forming load, metal flow pattern and alike, using aluminum 1072 as billet material for manufacturing SCCCH, along with micro-structural validation by experimental die-punch setup and simulation using modelling software DEFORM3D. Numerical analysis was also performed to estimate the forming load and metal flow patterns. Good number of experiments has been carried out at various punch movements to find out forming load and metal flow pattern. Microscopic analyses have been performed to validate the data with the results obtained from the experimentation. It was found that the numerical data was well validated with the experimental results. Further, Micro-hardness analysis was also performed. As the component was manufactured on application of heavy loads, the residual stress was also found to check the load carrying capacity of the component.