Investigation of Forward–Backward–Radial Extrusion Process of Aluminum Alloy Wheel Hub

As a kind of extrusion process, the forward–backward–radial extrusion (FBRE) process can be used to produce complex-shaped parts with hoop protrusions or flanges. The control of metal flow is the key to affect forming, strain distribution, and forming load during the FBRE process. On the basis of summarizing the research of the FBRE process, this paper presents the numerical and experimental results of aluminum alloy hub production using this method. Material flow behavior and strain distribution within the final product were investigated by finite element methods. The parameters such as billet size, die corner radius, and friction conditions are optimized and determined to control the material flow in different sections. While the uniformity of extrusion deformation is greatly improved, the extrusion forming load is reduced, and the aluminum alloy hub was manufactured by the FBRE process. The comparison between the theoretical and the experimental results shows good agreement.