An upper bound analysis of channel angular pressing process considering die geometric characteristics, friction, and material strain-hardening

Abstract

In this research, an upper bound (UB) analysis of channel angular pressing process was carried out considering die geometric characteristics including die angle, thicknesses of the inlet and the outlet channels, radiuses of outer and inner corners, length of the outlet channel, as well as the length of initial billet, friction and strain-hardening of material, under cold conditions and for a billet with a rectangular cross-section. To validate the results of the UB analysis, the result of the analytical equations was compared with that of the numerical simulation and actual process. The results revealed that the total plastic strain and the process force were augmented by reducing the die angle, the outlet channel thickness, and the outer corner radius, as well as by increasing the inlet channel thickness and the inner corner radius. It was also shown that the process force increased with augmenting the initial billet length. A very good agreement was obtained between the results of the analytical method and numerical and experimental methods.