Experimental Study and Simulation of Effects of Entrance Angle and Bearing Length on Force and Dimensional Accuracy in Extrusion Process

The extrusion process is one of the metal forming methods used to reduce the thickness or cross-section of the material. In current research, a lead rod with circular cross-section is converted to a square shape by passing through an extrusion die. Various parameters affect the extrusion process, including the bearing length, die entrance angle, press velocity, and lubricant type. In this paper, the effects of the entrance angle and the length of the deformation zone (bearing length) are studied experimentally and numerically on the dimensional accuracy of the deformed specimens and the forming force. For this purpose, four dies with bearing lengths of 2 and 5 mm, and an entrance angles of 30 and 45 degrees are used. Based on the results, it can be concluded that by decreasing the entrance angle and increasing the bearing length, the dimensional accuracy of the product will be increased and the highest force will be required during the forming process.