Amirkabir Journal of Mechanical Engineering

Amirkabir Journal of Mechanical Engineering

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, Technical and Vocational University (TVU), 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%.
Keywords
Subjects

[1] V. Modanloo, B. Akhoundi, and Y. Dadgar Asl, Minimizing the required forming force in the sheet hydroforming process using a fractional factorial design, Iranian Journal of Manufacturing Engineering 9(12) (2023) 1–9, (in Persian)
[2]  V. Modanloo, V. Alimirzaloo, and M. Elyasi, Optimal Design of Stamping Process for Fabrication of Titanium Bipolar Plates Using the Integration of Finite Element and Response Surface Methods, Arabian Journal for Science and Engineering 45 (2019).
[3]  E. Haddadi, H. Jafarzadeh, and M. Shameli, Numerical and Experimental Study of Backward-Radial Extrusion Process for Flanged Brass Alloy C26000 Parts, Journal of Materials Engineering and Performance (2025) 1–22.
[4]  M. Beyranvand and H. Haghighat, A New Deformation Model for Bimetal Tubes Extrusion Process, Amirkabir Journal of Mechanical Engineering 49(4) (2018) 819–828, (in Persian)
[5]  J. Seyed Mohammad and N. Ali Mohammad Naserian, Numerical and experimental investigation of non-Newtonian high viscosity flow field in multi materials extrusion process, Amirkabir Journal Mechanical Engineering 51(6) (2020) 121–130, (in Persian)
[6]  s. Hosseinzadeh, A. Davari, and A.H. Hashemian, Experimental and Numerical Analysis of the Extrusion Process in the Forming of Metal Composite metal billets, Modares Mechanical Engineering 24(2) (2024) 119–129, (in Persian)
[7]  A. Samadi Gooshchi, K. Abrinia, and M.K. Besharati Givi, Analysis of Three Dimensional of Forward Extrusion using Slab Method and Finite Element, University College of Engineering 43(4) (2009) 527–535.
[8]  H. Haghighat and H. Shayesteh, Upper bound analysis for hybrid sheet metals extrusion process through curved dies, Transactions of Nonferrous Metals Society of China 24(10) (2014) 3285–3292.
[9]  J.H. Shim, J.H. Ok, H.J. choi, H.S. Koo, and B.B. Hwang, A process sequence design of multi-step cold extrusion process for hollow parts, in Materials Science Forum 475 (2005) 4195-4198.
[10] A. Buschhausen, K. Weinmann, J.Y. Lee, and T. Altan, Evaluation of lubrication and friction in cold forging using a double backward-extrusion process, Journal of materials processing technology 33(1-2) (1992) 95–108.
[11] M.S. Joun, M.C. Park, Y. Heo, and D.H. Kim, A Review of Friction and Lubricant in Metal Forming. Lubricants 13(12) (2025) 512.
[12] Y. Sagisaka, et al., Evaluation of environmentally friendly lubricants for cold forging, Journal of Materials Processing Technology 212(9) (2012) 1869–1874.
[13] A. Yahaya,  S. Samion, N.A.M. Ahyan, and M.K.A. Hamid, Cold extrusion using biodegradable oil as lubricant: Experimental and simulation analysis, Jurnal Tribologi, 30 (2021) 116–132.
[14] A.L. de Moraes Costa, U.S. da Silva, and H.S. Valberg, On the friction conditions in FEM simulations of cold extrusion, Procedia Manufacturing 47 (2020) 231–236.
[15] H. Hou, L. Zhang, X. Wang, M. Mei, and Y. Zhao, Numerical and experimental research of the effect of friction on cold extrusion internal thread process, Journal of the Brazilian Society of Mechanical Sciences and Engineering 46(8) (2024) 515.
[16] M. Lotfi, S. Gasemi Benadkoki, M. Kalantar, Investigation of the Effect of Intercritical Annealing Heat Treatment on the Microstructure and Mechanical Properties of CK45 Steel Compared to Quench and Temper Conditions, in The First National Conference on Advanced Materials (2020) 45–58.