Finite element analysis of cold forward extrusion of 1010 steel

Résumé

Reliability of FE simulation of metal forming processes depends critically on the proper definition of material properties, the friction boundary conditions and details of the FE approach. To address these issues, the room temperature strain hardening behaviour of 1010 steel was established by performing a uniaxial compression test for the true strain of up to 1.5. Friction was evaluated using a ring test, with the two faces of the ring coated with a phosphate conversion layer and soap; the friction experimental results were matched with the FE established reference curves. The experimentally obtained material and friction input data were used in FE simulation, employing Arbitrary Lagrangian Eulerian adaptive meshing, to provide a valuable insight into the process of forward extrusion of an industrial component.