Abstract

Experimental and numerical prediction of extrusion load at different lubricating conditions of aluminium 6063 alloy in backward cup extrusion

Highlights

  • In the press design, the most important parameter that affects the final integrity and the structure of the final product is the extrusion load

  • The extrusion loads versus punch displacements or stroke curves for the aluminium alloy AA6063 in backward cup extrusion at room temperature comparing the curves at different strain rates for the different lubricants

  • The determination of plastic deformation has been achieved through various methods, especially through backward cup extrusion processes

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Summary

Introduction

The most important parameter that affects the final integrity and the structure of the final product is the extrusion load (i.e. deformation load). The effects of various lubricating conditions were investigated by Ikumapayi et al, (2019) on aluminum AA6063 alloy during the backward cup extrusion process to determine the temperature distribution during deformation. Abrinia and Gharibi (2008) use an upper bound model (UBM) and finite element method (FEM) in their research to analyse thin-walled cans during the backward extrusion process Their result shows that consistent and smaller can wall thickness can be achieved by using the appropriate punch head profile. Palm and olive oil yields the least deformation load than others, greater hardness and higher homogeneity were observed within the rod at the tensile stain side than the compressive side The focus of this investigation is to determine the extrusion load for the aluminum alloy AA6063 using an unconventional backward extrusion process (i.e. backward cup extrusion, BCE) at different lubricating conditions that allows considerably increased strength because of grain size reduction. The plastic deformation process during cold extrusion for technical-economic evaluation of materials can be found in (Herold et al, 2018) and the isothermal extrusion using the surface formation of the extrudate and flow pattern of material methods (Peng & Sheppard, 2004)

Extrusion material and lubricants selection
The extrusion punch and rig design
The punch designs
The lower die
Determination of extrusion force
Determination of shell diameter
Experimentation
Results and discussions
Extrusion load – stroke curves
Comparison of FEA simulation result and experimental result
Conclusion
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