The thesis is concerned with the analysis of axisymmetric forward extrusion by using the method of weighted residuals.
In the method of weighted residuals, flow function and stress function are assumed to cover the global control volume. The derived stress and strain components are used to formulate a yield equation in the error form, so that the error is minimized to determine stress and strain components. The method of least squares is chosen for the minimization of error.
The distribution of stresses and strains and the forming load are determined for the workhardening material considering the frictional effect at the die material interface. Some reduction of area and die shapes are chosen for computation. The computed results are very similar to those obtained by the finite element method.
The program is simpler in application and input control and requires less computation time than FEM.
Experiments are carried out for aluminium and steel specimens using conical and curved dies. It is found that the experimental observation is mostly in agreement with the computation by the method of weighted residuals.