Dimensional error prediction of cold formed components in backward extrusion using finite element analysis

This paper investigated the dimensional errors of cold-formed components due to elastic-plastic behaviour and temperature variations of workpiece and the elastic deformation of tools. A coupled thermal and mechanical Finite Element (FE) modelling procedure was developed to predict the dimensional deviations of the formed components. During an entire cold forming cycle, the material flow, temperature and stress distributions, tool deflections and dimensional errors of a backward extruded cup were evaluated. This enables a quantitative understanding of dimensional errors of the formed components with a view of forming stages and properties of the workpiece.