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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025

p-ISSN: 2395-0072

www.irjet.net

Simulation and Experimental Analysis of Combined Extrusion Forging Prakash Kumar Gupta-Madhur Srivastava 1M.Tech (CAD CAM) Scholar, Department of Mechanical Engineering, Ambalika Institute of Management &

Technology, Lucknow, Uttar Pradesh, India

2 Assistant Professor, Department of Mechanical Engineering, Ambalika Institute of Management & Technology,

Lucknow, Uttar Pradesh, India ---------------------------------------------------------------------***-------------------------------------------------------------------- By use of plastic deformation process, which Abstract- The modern manufacturing sector faces

maintain the mass and quantity of metal, the metal moved and flowed plastically in different directions.

several obstacles in its quest to create goods with high strength, low production costs, and resistance to heat, corrosion, and fatigue. When compared to other manufacturing processes like machining, casting, etc., the combined extrusion-forging method is used to overcome these issues by achieving enhanced material qualities, high production rates, and reduced material waste. The Combined Forging and Extrusion Process is a sophisticated method of metal formation in which the required result is obtained by forcing an initial billet through die punch setups for both extrusion and forging. The shape of dies, the percentage area reductions, and the frictional conditions at the workpiece/die contact are the key determinants of the metal flow pattern. Because of the complexity of the study and the sheer quantity of process elements involved, generating load estimation in this process can be challenging. It is widely used in the aerospace and automotive sectors. The current study focuses on estimating the forming load required to employ this procedure to make the product, a collet chuck holder. Both computational and experimental study have been done on the metal flow pattern and die cavity filling. For 3D modelling, Solidworks is the modelling programme of choice, while Deform3DTM is utilised for Simulation. Numerous experiments have been conducted in order to compare the outcomes of the Simulation process. There is a strong correlation between the outcomes of the Simulation analysis and the experimental.

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Application of the Combining Extrusion and Forgingmethod to a collet chuck holding is a manufacturing method that combines two different processes into one high-quality product. A billet of material is driven through a die during the extrusion process to create a continuous profile with a consistent cross-section. This technique is often used to produce tubular or cylindrical objects with good surface polish and regular proportions. In contrast, The process of forging metal involves applying high compressive forces. Usually, the material is heated to increase its malleability before being pressed or hammered into the required form. By aligning the grain structure and enhancing the material's strength and toughness, forging may improve its mechanical qualities. Manufacturers may achieve higher mechanical qualities, dimensional precision, and surface polish in collet chuck holders by combining the benefits of forging and extrusion. This hybrid technique ensures the durability needed for demanding applications and enables the economical manufacturing of complicated forms with tight tolerances.

Keywords: Finite Element Analysis (FEA), forming load, metal flow pattern, effective strain, Combined extrusion and forging process, and extrusion forging process.

1. INTRODUCTION

A number of procedures have developed for specific uses in metal working. These procedures can be divided into a few groups according to the kinds of forces that are applied to the workpiece. The following are these categories:

In addition to their strength, availability, and other qualities, metals are important in modern technology because they are easily moulded into useful shapes such as sheets, rods, and tubes.

Compared to casting and machining, deformation methods yield metal geometries with superior mechanical qualities. Advanced metal forming usually involves casting the metal into a shape that is almost identical to the final product, then further deforming it

Three basic procedures may be used to make extensive use of metal shapes: 

By metal casting, which involves preparing and pouring molten metal into a mould.

Impact Factor value: 8.315

By machining procedures, which involve removing material to form it into the appropriate shape, or by removal of metal.

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