A simple criterion for predicting the initiation of central burst in extrusion is proposed. The geometric conditions to avoid central bursting are predicted by using the proposed criterion under various process conditions and material properties. The optimal die profiles which minimize the extrusion power are also obtained for various process conditions. The mixed (pressure-velocity) formulation is used along with the Householder method to solve the resulting equations. It is shown that the optimal die profiles satisfy the conditions for prevention of central burst. The predictions based on the proposed criterion are in good agreement with the experimental observations and are in conformity with the results published earlier.

1.
Alberti
N.
,
Barcellona
A.
,
Masanata
A.
, and
Micari
F.
,
1993
, “
Central Bursting Defects in Drawing and Extrusion: Numerical and Ultrasonic Evaluations
,”
Annals of the CIRP
, Vol.
42
,
1
, pp.
269
272
.
2.
Arora, J. S., 1989, Introduction to Optimum Design, McGraw-Hill, pp. 301–303.
3.
Avitzur
B.
,
1968
, “
Analysis of Central Bursting Defects in Extrusion and Wire Drawing
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
90
, pp.
79
91
.
4.
Avitzur, B., and Talbert, S. H., 1989, “Upper-Bound Solutions and the Balance-of-Power Approach,” Plasticity and Modern Metal-Forming Technology, T. Z. Blazynski, ed., Elsevier Applied Science Publishers, London and New York, 1989, p. 32.
5.
Balaji
P. A.
,
Sundararajan
T.
, and
Lai
G. K.
,
1991
, “
Viscoplastic Deformation Analysis and Extrusion Die Design by FEM
,”
ASME Journal of Applied Mechanics
, Vol.
58
, pp.
644
650
.
6.
Bathe, K. J., 1982, Finite Element Procedures in Engineering Analysis, Prentice-Hall of India Private Limited, New Delhi, 1990.
7.
Chen
C. T.
, and
Ling
F. E.
,
1968
, “
Upper Bound Solutions to Axisymmetric Extrusion Problems
,”
International Journal of Mechanical Sciences
, Vol.
10
, pp.
863
879
.
8.
Clift
S. E.
,
Hartley
P.
,
Sturgess
C. E. N.
, and
Rowe
G. W.
,
1990
, “
Fracture Prediction in Plastic Deformation Processes
,”
International Journal of Mechanical Sciences
, Vol.
32
, pp.
1
17
.
9.
Devenpeck
M. L.
, and
Richmond
O.
,
1965
, “
Strip-Drawing Experiments with a Sigmoidal Die Profile
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
87
, pp.
425
428
.
10.
Gunesekera
J. S.
, and
Hoshino
S.
,
1982
, “
Analysis of Extrusion or Drawing of Polygonal Sections Through Straightly Converging Dies
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
104
, pp.
38
44
.
11.
Gunesekera
J. S.
, and
Hoshino
S.
,
1985
, “
Analysis of Extrusion of Polygonal Sections Through Streamlined Dies
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
107
, pp.
229
233
.
12.
Hoffmariner, A. L., 1971, “The Use of Workability test Results to Predict Processing Limits,” Metal Forming Interrelation Between Theory and Practice, H. L. Hoffmanner, ed., Plenum Press, New York and London, 1971, pp. 349–391.
13.
Joun
M. S.
, and
Hwang
S. M.
,
1993
a, “
Optimal Process Design in Steady-State Metal Forming by Finite Element Method—I. Theoretical Considerations
,”
International Journal of Machine Tools and Manufacture
, Vol.
33
, No.
1
, pp.
51
61
.
14.
Joun
M. S.
, and
Hwang
S. M.
,
1993
b, “
Optimal Process Design in Steady-State Metal Forming by Finite Element Method—II. Application to Die Profile Design in Extrusion
,”
International Journal of Machine Tools and Manufacture
, Vol.
33
, No.
1
, pp.
63
70
.
15.
Oh
S. I.
,
Chen
C. C.
, and
Kobayashi
S.
,
1979
, “
Ductile Fracture in Axisymmetric Extrusion and Drawing, Part 2: Workability in Extrusion and Drawing
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
101
, pp.
23
44
.
16.
Reddy
N. V.
,
Dixit
P. M.
, and
Lai
G. K.
,
1995
, “
Die Design for Axisymmetric Extrusion
,”
Journal of Materials Processing Technology
, Vol.
55
, pp.
331
339
.
17.
Richmond
O.
, and
Morrison
H. L.
,
1967
, “
Streamlined Wire Drawing Dies of Minimum Length
,”
Journal of the Mechanics and Physics of Solids
, Vol.
15
, pp.
195
203
.
18.
Sortais
H. C.
, and
Kobayashi
S.
,
1968
, “
An Optimum Die Profile for Axisymmetric Extrusion
,”
International Journal of Machine Tool Design and Research
, Vol.
8
, pp.
61
72
.
19.
Yang
D. Y.
,
Han
C. H.
, and
Lee
B. C.
,
1985
, “
The use of Generalised Deformation Boundaries for the Analysis of Axisymmetric Extrusion Through Curved Dies
,”
International Journal of Mechanical Sciences
, Vol.
27
, pp.
653
663
.
20.
Yang
D. Y.
, and
Han
C. H.
,
1987
, “
A New Formulation Of Generalised Velocity Field for Axisymmetric Forward Extrusion Through Arbitrarily Curved Dies
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
109
, pp.
161
168
.
21.
Yang
D. Y.
,
Lee
C. M.
, and
Cho
J. R.
,
1990
, “
Analysis of Axisymmetric Extrusion of Rods By The Method of Weighted Residuals using Body-Fitted Coordinate Transformation
,”
International Journal of Mechanical Sciences
, Vol.
32
, pp.
101
114
.
22.
Zimerman
Z.
, and
Avitzur
B.
,
1970
, “
Metal Flow Through Conical Converging Dies—A Lower Upper Bound Approach using Generalized Boundaries of the Plastic Zone
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
92
, pp.
119
129
.
This content is only available via PDF.
You do not currently have access to this content.