An experimental study of lateral extrusion of splines

The aim of this study is to investigate the lateral extrusion of splines in terms of load requirement and die filling. The prediction of forming load and pressure is an important task in metal forming. The upper bound method has been employed to investigate the load requirement for different process parameters, to this effect, kinematically admissible velocity fields have been developed. A series of experiment has been carried out using solid lead billets with two different diameters. The theoretical prediction of forming load is compared with experimental results. The predicted load values are higher than the experimental values during the tooth formation period but lower than the experimental values during the corner filling stage. Metal flow in the tooth region is not uniform and barreling occurs due to frictional resistance between the workpiece and the die gap surface. The barrel profile is assumed as a second order polynomial and a simple empirical relationship between the tooth dimensions and the barrel profile has been given using experimental data.