Modelling of cold extrusion with experimental verification

This paper reports on an experimental and finite element analysis (FEA) of the cold extrusion of high-grade (AA1100) aluminium. The influence of die angle, reduction ratio and die land on the extrusion force during the extrusion process was investigated. A forward extrusion die was designed and manufactured for the purpose of the experimental research. Interchangeable elements of the extrusion die allowed rapid change of the extrusion parameters to attain a high degree of experimental flexibility. A load cell, incorporated into the die design, allowed accurate determination of extrusion forces while a linear variable differential transformer (LVDT) provided automatic measurement of punch travel during the extrusion cycle. All data obtained from the instrumentation was captured and analysed using a personal computer (PC).