INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND MECHANICAL ENGINEERING Vol.1 Issue.2, May- June 2013. Pgs: 1-8 U.C. Paltasingh, S.K. Sahoo, P.R. Das, K.C. Nayak, S. Potnuru 1 ISSN (ONLINE): 2321-3051 INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND MECHANICAL ENGINEERING Lateral Extrusion for Round to-Triangular Head: Experimental Studies and Three Dimensional Analyses U.C. Paltasingh 1* , S.K. Sahoo 2 , P.R. Das 3 , K.C. Nayak 2 , S. Potnuru 2 1 Department of Mechanical Engg, Padmanava College of Engg, Rourkela-769002, Odisha, India, ucpaltasingh69@gmail.com 2 Department of Mechanical Engg, NIT Rourkela, 769008, Odisha, India, sks@nitrkl.ac.in 3 Department of Mechanical Engg, VSSUT Burla, 768018, Odisha, India, prdash_india@yahoo.co.in *Author Correspondence: Department of Mechanical Engg, Padmanava College of Engg, Rourkela-769002, Odisha, India, Telephone no. 919861089277, ucpaltasingh69@gmail.com Abstract In recent years, applications of integral part instead of assembled part in different industries have been increased. In the present work, an experimental die-punch set-up for lateral extrusion is designed and the process is simulated using finite element method for estimation of load requirement and metal flow patterns. Experimental study has been carried out to find the extrusion load at different geometrical conditions taking lead as the work piece material. The predictions both in extrusion/forging load and the deformed configuration are in good agreement with the experiment qualitatively under different conditions. Keywords: Lateral extrusion, Metal forming, Die-punch, Metal flow, Finite element method 1. Introduction Extrusion is a common metal-forming process in which the material is extruded by forcing it to flow through a shaped opening called die. Usually, a container is required to hold the billet in position before entering the die opening. Depending on the forming direction, it is classified as forward, backward and radial or lateral extrusion (Lange, 1985). Among these processes, radial extrusion is a forming process in which the punch moves axially causing the solid cylindrical or tubular billet to flow in radial direction into the die cavity and offers a product with a central boss section having complete or segmented protrusions. The research work for lateral extrusion is not as