Numerical and experimental investigations on an extrusion process for a newly developed ultra-high-carbon lightweight steel for the automotive industry

Abstract

In this study the material flow of a newly developed ultra-high-carbon lightweight steel (uhc-steel) with a high amount of aluminum was investigated in an extrusion process. Cylinder compression tests were performed for material characterization and frictional behaviour was determined by using ring compression tests. Numerical simulations were carried to determine the optimal die geometry as well as to calculate the process loads and dominated stresses in the die occurring during the process. Based on the numerical results, an extrusion process was designed and implemented. Experiments showed that the uhc-steel can be formed by extrusion however it is associated with a high wear rate.