A Numerical and Experimental Analysis on the Forming Limit of AA 3105 Aluminum Alloy in Radial Extrusion Process

Abstract

In this paper, the forming limit of flange in radial extrusion process was analyzed by the rigid-plastic finite element method. The selected model material for simulation and experiments was AA 3105 aluminum alloy. The predictions from simulation were made in terms of axial and circumferential strains. Experiments also have been conducted to compare with the simulation results with regards to deformation pattern. Furthermore, the deformation pattern in forming of flange section was closely investigated and categorized in three cases such as sticking, separating and cracking. The analysis in this paper is focused on the transient extrusion process of material flow into the gap in radial direction for different gap heights and die corner radii. The results of present study were summarized in terms of evolution of surface strains in axial and circumferential directions measured from the finite element meshes located in the region where surface cracking occurred in experiments. The forming limit line was drawn in the relationship of circumferential and axial strain. It was concluded from this study that the forming limit line is influenced mainly by circumferential strain on free surface of flange. It was also predicted that ductile fracture on flange surface is likely to occur in the middle of flange gap under the condition of sticking deformation and near bottom of flange gap under the condition of separating deformation, respectively. The forming limit of flange in terms of flange diameter was expected about 2.5do, which is 2.5 times the diameter of original billet.