Effects of lubricants and billet geometry on the extrusion of AA6063/5% SiCp composites

In aluminium extrusion process, metal flow is greatly controlled by the die geometry and a variety of intricate profiles can be achieved by designing dies of different configurations. In porthole die extrusion, number of portholes used for a profile is often determined by the subjective knowledge of designers. Nevertheless, extrusion load and weld strength of profile produced are not only dependent on extrusion ratio, temperature of deformation but also on the number of portholes along with other die geometry variables. In the present investigation, systematic studies were carried out on three different dies with four ports, three and two ports around die center to extrude profiles of outer diameter 29.4 mm and thickness 2mm. Numerical simulations were carried out for estimation of pressure, temperature, strain, and strain rate parameters in the weld chamber for all the dies, followed by press trials and profiles produced were subjected to wedge expansion test. The results from numerical simulations indicated that pressure generated inside weld chamber increases with number of portholes. The surface plots indicated highest pressure of about 280 MPa for four port hole and about 276 MPa for three ports die and pressure of about 160 MPa was estimated for two port hole die at the entry of weld chamber , which is 65mm from profile end. Similarly, temperature at profile exit was 551 0C for four portholes die and 546 0C for three portholes die and 537 0C for two portholes die. Furthermore, press trials indicated peak extrusion loads of 5241 kN, 4406 kN and 3961 kN respectively for four, three and two portholes die. Thus, the peak extrusion load decreased by about 16 % for three port and about 25 % for two ports die in comparison with four port die. Also, the extruded profiles in wedge expansion test indicated mean compression load of 22.70±0.14 kN in four porthole die, mean compression load 22.29±0.26 kN for three port die and mean compression load of 17.841± 0.27 kN.

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An Investigation into the Heat Deformation of a Powder-Metallurgical Iron- Aluminium-Chromium Alloy

Francis Xavier,

Sambath,

Jayabalakrishnan

et al. 2024

SAE Technical Paper Series

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<div class="section abstract"><div class="htmlview paragraph">Powder metallurgy of 3065IS temperature and strain rate were only two of the variables used to investigate the higher permeability of an iron alloy. A strain rate vs. stress plot revealed a critical value. This demonstrated that the functioning of the alloy was comparable to that of other materials in its class. We used a transmission electron microscope to examine the microstructure of routinely twisted materials to determine particle characteristics and precipitate distribution. This allowed us to gain a better understanding of the internal workings of materials. Using constitutive equations, we investigated the link between temperature and stress. This study's findings were incorporated into equations describing the material's high thermal behaviour, and a modified version of the cosec equation was used to analyse this reliance. Effective stress was defined as the distinction between actual stress and a present limit. It has been shown that the presence of ferrous particles and deposited inter - metallic phase may result in a continuous threshold stress that changes with temperature. The temperature of a material influences the stress applied to it.</div></div>

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Effects of lubricants and billet geometry on the extrusion of AA6063/5% SiCp composites

Cited by 3 publications

References 32 publications

Experimental analysis of Al composites toughened by aluminium oxide and graphite using stir casting progression

Experimental analysis of Al composites toughened by aluminium oxide and graphite using stir casting progression

Numerical and experimental investigations on AA6063 extrudates: effect of number of portholes on extrusion load and weld strength

An Investigation into the Heat Deformation of a Powder-Metallurgical Iron- Aluminium-Chromium Alloy

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