Experimental studies of the force to extrude a rate sensitive material

Abstract

Distinctions are drawn between three mean strain rates in extrusion: those averaged over the accumulated strain, the distance travelled through the die, and the elapsed time. It is shown that when the strain rate varies, the mean strain rate based on strain is always the greatest, and the mean strain rate based on time the smallest. Three further mean strain rates are introduced, which are root mean power (RMP) values of the above strain rates. Conventional estimates of the extrusion pressure for frictionless, homogeneous flow are based on rate insensitive analyses and lead to pressures proportional to the mean strain rate based on time. When the rate sensitivity during flow is taken into account, the calculated pressure is shown to be a function of the RMP strain rate based on accumulated strain, which is considerably greater than the mean strain rate based on time. Experiments are described in which ice was extruded by the indirect process, leading to nearly frictionless, homogeneous flow. Extrusion ratios of 4, 9, 25, 81, and 144 were used. In the first series of experiments, the ram velocity was adjusted to give the samerate insensitive (i.e. time-based) mean strain rate for all the dies. In the second series of experiments, the ram velocity was adjusted to give the samerate sensitive (i.e. RMP) mean strain rate for all the dies. In all cases the extrusion pressure was proportional to the RMP strain rate and not to the time-based strain rate. The rate sensitivity correction factor is also described.