Some aspects on cold forging of aluminium–iron powder metallurgy composite under triaxial stress state condition

An experimental investigation on the barreling of aluminium with various per cent additive of iron composites, namely, 2%, 4%, 6%, 8% and 10% with different iron particle sizes, namely −53 +45 μm, −75 +63 μm and −106 +90 μm under triaxial stress state condition has been studied in the present work. Sintered aluminium–iron composites with height to diameter ratio of 0.44 were prepared, sintered, furnace cooled and cold upset forged. A new empirical relationship for the determination of the barrel radius is proposed based on the circular radius of curvature and compared with the experimentally measured barrel radius. Various stress ratio parameters, namely (σθ/σz), (σm/σz), (σeff/σz) and (σm/σeff), respectively, were determined and their behaviour against the relative density and barrel radius has been systematically analyzed. A straight-line relationship was observed for the measured and the calculated radius of curvature of barrel and an exponential relationship was found between the stress ratio parameters and the relative density.