Abstract
Friction stir extrusion is an innovative direct-recycling technology for metal machining chips. During the process a specifically designed rotating tool is plunged into a cylindrical matrix containing the scraps to be recycled. The stirring action of the tool prompts solid bonding related phenomena allowing the back extrusion of a full dense rod. This process results to be particularly relevant because allows the reuse of the scrap without any previous treatment. Experiments have been carried out in order to investigate the influence of the process parameters on the extrudes quality and a numerical model has been developed in order to simulate the evolution of the material flow.
Highlights
The production of most mechanical component requires machining operation, usually implying the cut material to be wasted as scrap during in traditional cutting processes [1]
In 1993 TWI patented a new recycling process to be applied to metal chips, named Friction Stir Extrusion (FSE)
This technique belongs to the Friction Stir Processing (FSP) technologies, developed following up the “Friction Stir Welding” (FSW)
Summary
The production of most mechanical component requires machining operation, usually implying the cut material to be wasted as scrap during in traditional cutting processes [1] The recovery of these materials results to be nowadays a crucial challenge in order to obtain both environmental and economic advantages leading many researchers and industries to look for innovative and effective recycling technologies. A rotating tool is used to produce heat and plastic deformation through friction between the tool itself and the chips to be recycled (into a hollow cylindrical matrix) by compacting, stirring and extruding the material. In this way, the recycling process takes place in a unique operation, resulting in significant cost, energy, and labor saving with respect to both conventional method and direct method. Numerical simulation was used to highlight the material flow during the process and identify the process mechanics leading to the formation of big SiC agglomerates in case of high initial percentage
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