Numerical analysis of tool geometry effect on the wear characteristics in a radial forward extrusion

The finite element analysis has been performed to investigate the tool wear characteristics in forming a central hub component with radial protrusion by a radial forward extrusion process. The main objective of this study is to investigate the influence of tool geometries on the wear characteristics of the mandrel and container surfaces. Two major process parameters such as annular gap height and mandrel diameter were adopted to examine the wear characteristics. SCM415H steel was selected as a model material in simulation by adopting the Archard's wear model, which was verified by comparing with experimental results in the literatures. The results of present study were summarized quantitatively in terms of wear profiles on the tool surfaces such as container and mandrel in terms of wear depth, contact pressure and sliding velocity. The localized wear depth is more sensitive to the variation of annular gap height with increase in mandrel diameter.