Optimisation of the lubrication for the extrusion of solid and tubular components by injection forging

FE simulations were conducted to assess the scale of friction-dependent pressure losses in the injection chamber during the injection forging of solid and tubular components. Several lubrication procedures were then tried with a view to establishing the 'optimal' lubrication which would result in a significant reduction of the friction in the injection chamber. A procedure which combined two lubricants was identified as being "optimal" for use in the extrusion of long, shaft-type components. The procedure enabled the pressure losses in the injection chamber to be reduced from 50 to 60% of the applied pressure to 4-6% of the pressure. Experiments and FE simulations of the forming of the tubular components confirmed the significant reduction of the forming force requirement and the improvement of the material flow by the developed procedure.