Design and finite element analysis of cold extrusion die to form the hollow shaft

Abstract

Extrusion of hollow shafts faces many issues such as ultimate tensile strength, less formability, residual stress, and fracture during manufacturing. The primary purpose of this study is to utilize finite element analysis to design a new die and form the hollow shaft that is absolutely freefrom fracture. Medium carbon steel (JIS G3445) was selected as the material for the hollow shaft and D2 carbide steel was selected as the die material. From this study, it was inferred that the shaft can be formed by applying two important process parameters such as taper angles and velocity in three subdivided die design stages. The shaft was formed with good formability, acceptable stress/strain distribution, and without any fracture. Hence the suitable die geometry for hollow shaft manufacturing in the cold extrusion process was identified using Abaqus simulation.