Abstract
This paper investigates the extrusion process to manufacture bimetallic cylinders combining a magnesium alloy core (AZ31B) and a titanium alloy sleeve (Ti6Al4V) of interest in aeronautical applications. A robust finite element model has been developed to determine the most influential parameters and to study the effect of them on the extrusion force and damage induced by means of Design of Experiments (DOE) and Taguchi method. The results show that the most influential parameters in the extrusion forces are the friction between sleeve and container/die and the height of the cylinder; and the less influential ones are the process temperature and ram speed. Moreover, minimum values of forces along with low damage can be reached by favorable interface contact conditions, minimizing the friction at the core-container/die interface, as the main influencing factor; followed by the geometrical dimensions of the billet, being the billet height more important when paying attention to the minimum forces, and being the core diameter when considering the minimum damage as the most important criterion. The results can potentially be used to improve the efficiency of this kind of extrusion process and the quality of the extruded part that, along with the use of lightweight materials, can contribute to sustainable production approaches.
Highlights
Development of multi-material parts has gained relevance during recent years due to the possibilities of adapting the mechanical properties of each material to the specific in-service requirements of the component
The direct extrusion of a bimetallic cylinder with a magnesium alloy AZ31B core and a titanium alloy Ti6Al4V sleeve has been analyzed by means of finite element simulation and the design of experiments (DOE) technique; special attention has been paid to the forces required and damage induced in order to determine the most relevant parameters to choose the most efficient operating conditions
The bimetallic cylinders used in the simulations have a magnesium alloy UNS M11311 core and a titanium alloy UNS R56400 as sleeve (Figure 1); due to their excellent properties, these alloys are well known in the industry by the nomenclature AZ31B and Ti6Al4V, respectively, so this will be the designation used in the paper on
Summary
Development of multi-material parts has gained relevance during recent years due to the possibilities of adapting the mechanical properties of each material to the specific in-service requirements of the component. Additive manufacturing techniques can be an alternative to conventional processes when design specifications of obsolete parts are difficult to obtain due to a lack of information, such as component drawings or bill of materials, as explained by Rodríguez-Prieto et al [4] The problem with these kinds of multi-material components is the limitation in their in-service behavior, as composite materials cannot be used for high temperature requirements. The direct extrusion of a bimetallic cylinder with a magnesium alloy AZ31B core and a titanium alloy Ti6Al4V sleeve has been analyzed by means of finite element simulation and the design of experiments (DOE) technique; special attention has been paid to the forces required and damage induced in order to determine the most relevant parameters to choose the most efficient operating conditions
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