FEM simulation and optimization on rotating extrusion of bi-metal rod with constant shear friction

Abstract

This study assuming constant shear friction adopts FEM simulation and the optimization to investigate into extrusion of bi-metal rod which consisted of Aluminum alloy (Core) and Copper alloy (Sleeve) with a rotating die taking tonto account the interface at bi-metal rod under the bonding situation. The forming characteristics, e.g. the effective stress, the effective strain, the velocity field, the extrusion force, the extrusion torque, and die stress can be gained by using FEM commercial software. The FEM optimization for extrusion force combines Taguchi method to establish the L934 orthogonal table that includes four control factors which are rotating angular velocity (ω), frictional factor at the interface of sleeve and die (m1), half die angle (α°), and inner die filet (R). The ranking of influence factors and the optimization combination can be obtained from FEM simulation to provide the reference to the industries.