Sheet metal extrusion is a process in which the extrusion punch penetrates one surface of the sheet metal material to cause it to extrude and flow toward the outlet of the die. In fact, this process is a combined process in which both extrusion and penetration occur at the same time. The process can be seen in production processes, such as in the forming of a protruding part on a strip material, in the pre-forming of a staged hole in a forming step with a progressive die, and in the forming of the extruded part in a combined fine-blanking and extrusion process. This paper presents the characteristics of the process and gives a detailed analysis of it with the finite element method. According to the results, the mesh distortion, the field of material flow, and the distributions of the stress and strain can be predicted. Analysing the results from simulation, it is proposed that the extruded material can be divided into five areas according to their different features of deformation. In addition, the material in the areas of deformation can further be divided into three parts according to their different features of compression and elongation. The location of the fracture has been predicted from simulations. Some experiments have been carried out to verify the simulated results. © 2005 Elsevier B.V. All rights reserved.
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