Analytical and Numerical Analysis of Extrusion Force, Stress and Strain Development During Extrusion Al6063-SiC Composite

Abstract

Nowadays composite material are highly interesting in different areas like, aerospace, thermal management, automotive application, and electronic products etc. Aluminium based metal matrix with silicon carbide as particle reinforcements called discontinuous reinforced metal matrix composite materials. It has excellent mechanical properties like high yield strength, wear resistance, corrosion resistance and vibration resistance. During the development of discontinuous reinforcement metal matrix composites compression process like, extrusion is an advisable secondary process for homogenous distribution of the reinforcement’s materials through the metal matrix. This research was investigated the metal flow behavior of extrusion load, stress and strain distribution of Al6063/Sic based discontinuous reinforcement metal matrix composite. The billets extruded from round billet to square shape and are used for different applications. Third order polynomial and cosine die profiles were used as extrusion dies for this research by taking 30%, 60% and 90% area reductions. Depends on these three different area reductions upper bound and DEFORM 3D finite element analysis method were used to analyze analytically and numerically respectively. Due to these different area reductions, the extrusion load was minimum in cosine die profiles both analytical and numerical results. In 30% of area reduction cosine die profile has optimum load (878.59N) and it used to extrude Al6063/20%SiC composite billet materials from 20mm input diameter to 14.8x14.8mm output square sides. Therefore, 30% area reduction cosine die profile has minimum extrusion load as compare other area reduction of cosine die and 3rd order polynomial dies. It is used as extrusion die for Al6063/SiC composite materials to optimum extrusion loads in different % of area reduction of square shape extruded.