Effects of Tool Coatings on Energy Consumption in Micro-Extrusion of Aluminum Alloy 6063

Abstract

The tool wear rate and energy consumption were typically unknown in micro-extrusion, which made it difficult to optimize the tool design for both the final part quality and production cost. This study investigated the effects of tool coatings on energy consumption in the micro-extrusion of aluminum alloy 6063. Three main factors were considered in this study: (1) tool coating types, (2) bearing length, and (3) extrusion ratio. The micro-extrusion finite element simulation model was developed and validated with the micro-extrusion experiment. The results showed that increasing bearing lengths led to the increase in tool wear rate and energy consumption for all the coating types. The decreasing coefficient of friction values of the tool-billet interface led to a decrease in energy consumption. High hardness values of the tool surface and low bearing lengths helped increase tool life. Low values of coefficient of friction and bearing lengths helped decrease energy consumption.