Investigations on the extrusion defect – Axial hole or funnel

Axial hole or funnel is a common extrusion defect observed during a direct extrusion process. Though a common defect, the parameters that influence the nature and formation of this defect have not been studied and reported. Further, the die design requirement to avoid the defect has also been not yet established. In this regard, finite element analysis has been carried out to investigate the effect of important extrusion parameters such as extrusion ratio (R), extrusion die angle (θ), deformation zone height (h), friction (μ) and constitutive material behaviour on the defect formation and its characteristic. The conditions under which the defect can be avoided have been established. Physical modeling experiments using plasticine were carried out to validate the numerical modeling results.