A study of lateral extrusion of gear like elements and splines

An upper bound solution for lateral extrusion of spline and spur gear forms has been developed. A simple kinematically admissible velocity field with optimization parameter is proposed. From the proposed velocity field the upper bound solution on relative punch pressure and extrusion load are determined with respect to chosen process parameters. The results are compared with theoretical and experimental results from a reference to illustrate the validity of the proposed velocity fields. This indicates that the analysis presented here renders better upper bound solution than that given by Plancak et al. [Non-conventional cold extrusion, J. Mater. Process. Technol. 34 (1992) 465–472].