Plane-strain forward extrusion of non-workhardening metal through a square die is analyzed theoretically under the assumptions that the velocity field is incompressible and irrotational and that the dead metal zone near each corner corresponds to the region at rest. The dead metal zone is determined to give the minimum extrusion pressure for a given extrusion ratio.
Theoretical results for extrusion pressure and grid line distortion show reasonably good agreement with experimental observations.
Simulated experiments are carried out with the beeswax for the various extrusion ratios. The shape of flow lines shows a good agreement with that of the practical extrusions.
