Abstract
In the present study, theoretical development proposed in previous work carried out in extrusion of clover sections in relation to a generalized die design method is presented in the extended scope for three-dimensional extrusion of trocoidal gear sections from round billets with experimental verification. Computations are carried out for clover and trocoidal gear sections. The CAD/CAM of the suggested dies is introduced for the experiments. Experiments are carried out for a clover section and a trocoidal gear section with eight teeth. Al 2024 aluminum billets were used as the working material. Half-cut specimens are used for flow visualization of the extrusion process. The theoretical predictions are in good agreement with the experimental results in extrusion load and metal flow.
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