Present manufacturing industries are facing many challenges to produce the products of high strength, resistance to fatigue, heat, corrosion and low production cost. To meet these challenges combined extrusion-forging process is employed to achieve improved material properties, high production rates, and less material wastage when compared with other manufacturing processes such as machining, casting, etc. Combined extrusion-forging process is the advanced metal forming process in which an initial billet is forced through the extrusion and forging die punch setup to get desired product. The flow pattern of metal mainly depends on the frictional conditions at the workpiece/die interface, the geometry of dies and the percentage area reductions. In this process, the estimation of forming load is a bit difficult because the number of process parameters involved, and complexness of analysis. It has extensive applications in automotive and aerospace industries. Present research work focuses on estimation of forming load to produce the product collet chuck holder by this process. The metal flow pattern and die cavity filling has studied in both experimental and simulation analysis. The modelling software Solidworks is used for 3D modelling and Deform3D® is used for the simulation process. The number of experiments has done to compare the results obtained from the simulation process. The results obtained from the experimentation and simulation analysis are in good agreement with each other.
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