FE analysis and experimental investigation of cold extrusion by shaped punch

The current paper deals with backward extrusion by punch with involute gear-profile. Process has been analyzed by two methods: FE simulation and experimentally. In order to perform experimental investigation special tooling was designed and made. Material of the billet was C1121 (low carbon steel) for which stress - strain curve has been obtained in the Rastegaev upsetting test. Total load and average punch pressure as well as the stress and strain distribution at the component cross – section, have been determined and compared with the values obtained by FE method. Obtained experimental results show fair agreement with FE results. Some observations regarding process development and process analysis have been made.