Experimental and Numerical Investigation of the Cold Extrusion of a Cup-Shaped Steel Joint Body and the Effect of Die Geometry and Lubrication Parameters

Document Type : Research Article

Authors

1 Department of Mechanical Engineering, National University of Skills (NUS), Tehran, Iran

2 Department of Mechanical Engineering, Islamic Azad University, Tabriz branch, Tabriz, Iran

Abstract

The feasibility of manufacturing a cup-shaped steel joint body for the Peugeot 405 vehicle from CK45 steel using the cold extrusion process was investigated through experimental and numerical approaches. The main objective was to analyze material behavior under different processing conditions and to evaluate the effects of key process parameters on the forming force and the final hardness of the component. After annealing, the initial billets were subjected to direct cold extrusion, and the results demonstrated that this process is fully capable of producing the complex geometry of the part. The findings revealed that variations in friction conditions, punch corner angle, and wall thickness have a significant influence on the process response. Decreasing the friction factor from 0.40 to 0.13 reduced the maximum punch load from 2450 to 1750 kN, while increasing the punch corner angle from 0° to 20° also reduced the extrusion force by approximately 56% and enhanced material flow. examination of the wall thickness effect revealed that increasing the wall thickness from 4.5 to 8.5 mm led to a decrease in forming load from 2700 to 1500 kN. Hardness measurements further indicated that an appropriate combination of friction conditions and effective lubrication enhances hardness uniformity and improves the final hardness of the extruded component. Numerical and experimental results from DEFORM software indicated that, difference in forming load between these methods was 10%.

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Amirkabir Journal of Mechanical Engineering
Volume 57, Issue 9
in progress
December 2025

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