Abstract :
The effects of material properties, elastic–plastic behaviour and temperature variations of the workpiece and tools on the dimensional errors of cold formed components are investigated in this paper. A finite element (FE) analysis procedure has been developed to predict component dimensional errors during different stages of the cold forming process. During an entire cold forming cycle for a forward extruded rod, the material deformation, heat generation, temperature distribution, and tool stress and deflections are evaluated. The dimensional errors of the formed component are also obtained, which enables a quantitative evaluation of the dimensional errors of the extruded rod. The effects of forming stages, material type, die deflections, friction, and thermal behaviour on the component dimensional errors are investigated.
