Extrusion process and parameters involved in the experimental and numerical investigation-review
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This document reviews extrusion processes and parameters for investigating aluminum alloys Al6061, Al6063, and Al7075. It discusses experimental and numerical methods used to study the effects of parameters like die angle, billet temperature, speed, and geometry. Taguchi methods were used to optimize parameters for Al6061 extrusion. Numerical analysis found the maximum stresses occur at square tube corners. The document concludes that smaller extrusion ratios and stresses result from thicker products and fixed billet dimensions. Parameters like die angle, temperature, speed, and geometry influence load, strength, and deformation during aluminum extrusion.
![International Journal of Engineering Research and Development
e-ISSN: 2278-067X, p-ISSN: 2278-800X, www.ijerd.com
Volume 11, Issue 06 (June 2015), PP.01-03
1
Extrusion process and parameters involved in the experimental
and numerical investigation-review
Sangamesh Sirsgi1
, Dr. Shrishail Kakkeri2
, Nagraj Patil3
Asst. Professor and HOD, Department of Mechanical, LAEC, Bidar1
Professor and HOD, Department of Mechanical, SVCE, Bangalore2
Asst. Professor SET, Jain University, Bangalore3
Abstract:- With the conventional extrusion process it is very difficult to produce a hollow section tubes, for
various types of Aluminium Alloys, such as Al6061, Al6063 & Al7075. Because of complicated structure of die
Assembly it is became mandatory to investigate experimentally. For 6061 Al alloy Taguchi Method is applied to
optimize the parameters involved in it. For other materials Numerical Analysis is carried out for investigation of
various parameters. In this review paper the discussion is carried out for Al6061,Al6063& Al7075 materials in
the extrusion process for investigating the different process parameters by Taguchi & Numerical Analysis
Method.
I. INTRODUCTION
Extrusion appears to be a means of breaking down as cast structure of billet being subjected to only
compressive forces in the extrusion process. In the cold extrusion, punches and dies are made up of wear
resistant tool steels such as high alloy chromium steels which are subjected to severe working conditions in
order to report dimensional stability and good surface finish.
Cold extrusion models to verify parameters that influence the process have been investigated. Qamar
[3], through a Finite Element Method (FEM) studied extrusion complexities and dead metal zone using
numerical simulations extrusion to validate experimental observations. Dies of three different profiles made of
H13 steel were used on lead and Al- 6063 alloy. Fluctuations in metal distortion during plastic flow and dead
metal zone size were observed. This shows the variation in die profile symmetry and extrusion ratio. Tiernan
used two different lubricants namely zinc stearate and oil based lubricant containing lead and copper additives.
The experiment was configured to analyze effects on the reduction ratio die angle and die length on the
extrusion force. Data obtained from experimental result and by computations using FEM predictive simulations
were compared. The highest extrusion force obtained by experiment. The force was measured when extruding
the aluminum billet using a die with exit diameter, die angle, and land height. In comparison of results,
reasonable correlations were observed to exist between FEM and experimental values of extrusion forces[1].
Aluminum extrusion is a single pass process to produce a long part with high accuracy and complex
cross sectional geometry. The only way to vary the cross section is by the use of extrusion die. A solid
cylindrical billet is heated and placed inside a container which is pushed by hydraulic punch is forced to flow
through die set. Therefore, products with varied cross sections such as rods, wires, sheets, tubes, hollow or non-
hollow parts can be fabricated [1]. In recent years, there are many researches analyzing plastic deformations as
well as die wear by finite element analysis[2].The basic process of extrusion is well described as a thermo-
mechanical event in a quite recent text which indicates that the mathematical description of the process is still
largely semi-empirical. The extrusion process is complex and involving interaction between the process
variables and the material‟s high temp properties. Theoretically the variables that can be controlled are the
extrusion ratio, the ram speed, and the initial extrusion temperature. However, events on the micromechanical
scale are still not sufficiently described. The most important of all these is possibly the mechanics at the
interface between tooling and material. This influences the analyses of the temperature changes occurring during
the process, the temperature and the temperature history determining the structure of the extruded and hence, to
a large extent, its properties.[3]
II. LITERATRE REVIEW
S. O. Adeosun et al [1] Have made an investigation of die entry angles 15o
, 30o
, 45o
,60o
,75o
& 90o
were
simulated. Improvement is observed with 45o
, 90o
& 75o
die entry angles. It is been observed that at 45o
die entry
angle the index of 2.1 for plain carbon steel die & 1.8 for steel die.
Quang-Cherng Hsu et al [2] Have investigated for Al7075 square tube with both simulation & experiment. In
this there are several factors which are taken for simulation & experiment are billet temperature, billet](https://image.slidesharecdn.com/a1160103-150807072108-lva1-app6891/85/Extrusion-process-and-parameters-involved-in-the-experimental-and-numerical-investigation-review-1-320.jpg)
![Extrusion process and parameters involved in the experimental and numerical investigation: review
2
dimensions, flow stresses, die cavity & product geometry. The material Al7075 behaves high forming resistant
when compared to Al6063 & Al6061.
Flitta et al[3] This investigation is mainly focuses on simulation of the extrusion process & in particular the
effect of the initial billet temperature on friction & its consequences on material. The simulation is validated
with experimental results. The effect of billet temperature both in simulation & experimentally are presented.
Rajamamundi Prabhu et al [4] Have gone through the forming of hollow section tubes that are very difficult
to produce by conventional extrusion with a mandrel on the stem. During the hot extrusion for Al6061 Alloy the
change of process parameters will effect to the mechanical properties. In this extrusion are tested for tensile test,
flattening test, expanding test using a conical punch, surface finish & micro-structure.
III. EXTRUSION PROCESS FOR ALUMINUMALLOY
A. Extrusion Process
This study uses direct extrusion or forward extrusion. The process is that when the billet is pushed in
the container, the ram keeps pushing forward, and then the material is extruded and flows out of the die outlet.
As the material flows out in the same direction as the ram moves, when the billet is about 20mm thick, the
extrusion stops, while the ram moves backward, another billet is put into the container, and then the ram presses
in the new billet. The process is then repeated, as shown in Figure. [2]
IV. FRICTION
The coefficient of friction at the metal billet interface contributes significantly to the difficulty of
extruding, and it is a point where the friction resistance approaches the shear resistance of the hot material
during the deformation. Furthermore it is a point where a fraction or all of the displacement of billet at the
interface occur by shear in its surface layers leaving a fragment of the billet deposited on the wall of the
container. In practice aluminium alloys are extruded without any lubricant or with only a small amount of
graphite applied to the die face. Finding a suitable lubricant would be adifficult task and in any case of un-
lubricated aluminium extrusion is desirable in order to prevent impurity pick up from the tools and to ensure that
all the material making up the extruded surfaces originates from material within the billet. Therefore the
interfacial conditions at the billet container interface during extrusion has a direct effect on metal the stresses
acting upon both the tools and within the material and hence load and energy requirements and extruded
temperature.
V. SELECTION OF CONTROL FACTORS
The objective of the present work is to identify the effect of convex die angle which would optimize the
load and tensile strength of hot extruded tubes. The process parameters generally considered for hot extrusion
process of Al 6061 alloy tubes using port hole die method include extrusion speed, die shape, billet temperature,
mandrel length, convex angle, tooling temperature, extrusion ratio, port hole number and mandrel shape etc. In
Taguchi method, the selection of influential parameters for analysis is a critical issue. For the present case, the
most influential process parameters for the analysis are selected based on studies reported in literature with main
focus on tensile strength and load characteristics and they are listed. These four input parameters are taken as](https://image.slidesharecdn.com/a1160103-150807072108-lva1-app6891/85/Extrusion-process-and-parameters-involved-in-the-experimental-and-numerical-investigation-review-2-320.jpg)
![Extrusion process and parameters involved in the experimental and numerical investigation: review
3
control factors and each factor has been considered with three levels. Since the number of degrees of freedom is
8, an orthogonal array (inner array) L
9
has been found suitable for the present design.[4]
VI. CONCLUSIONS
1) In this extrusion process the thickness of the product is varied and other parameters are kept remain same.
2) If we consider billet dimension for fixed condition, we get smaller extrusion ratio for thicker product & also
smaller stress in the die.
3) With the numerical analysis the maximum stress is on corners of the square tube which is same for the
experimental method.
REFERENCES
[1]. O.P. GbeneboroSekunowO.I. , S. O. Adeosun, Effect of Die Entry Angle on Extrusion Responses of
Aluminum 6063 Alloy International Journal of Engineering and Technology Volume 4 No. 2,
February, 2014
[2]. Quang-Cherng Hsu, Kun-Hong Kuo, Ping-HsunTsai Square Tube Manufacturing for Al7075 by
Forward Extrusion with Porthole Die
[3]. I. Flitta and T. Sheppard Nature of friction in extrusion process and its effect on material, Manuscript
received 15 May 2002; accepted 16 December 2002.# 2003 •
[4]. RajamamundiPrabhu
1
and V.S. K. Venkatachalapathy “EFFECT OF CONVEX DIE ANGLE OF
PORTHOLE DIE ON PLASTIC DEFORMATION AND EXTRUSION PROCESS IN TUBE
EXTRUSION”ARPN Journal of Engineering and Applied Sciences, VOL. 5, NO. 12, DECEMBER
2010
[5]. flittaand t. sheppard: Proc. 7th Int. Seminar onAluminium extrusion technology‟ Chicago, 197 – 203;
2000,Washington, DC, TheAluminium Association.
[6]. flittaand t. sheppard: Proc. 5th Int. ESAFORM Conf.,Krakow, Poland, April 2002, European Scienti.c
Associationfor Material Forming, 435 – 438.
[7]. chanda, j. zhou, l. kowalsiand j. duszczyk: Sci. Mater.,1999, 41, 195 – 202.
[8]. j. e. van rens, w. a. m. brelemansand f. p. t. baajens:Proc. 7th Int. Seminar on „Aluminium extrusion
technology‟,Chicago, 99 – 107; 2000, Washington, DC, TheAluminiumAssociation.
[9]. a. dean and z. m. hu: Proc. 6th Int. Conf. on „Technologyof plasticity‟, Nuremburg, Germany,
September 1999, Vol. 1,541 – 550; Springer – Verlag.
[10]. s. abtahi, t. weloand s. storen: Proc. 6th Int. Seminar onAluminium extrusion technology‟, Chicago,
125 – 131; 1996,Washington, DC, TheAluminium Association.
[11]. t. welo, t. s. abtahiand i. skauvik: Proc. 6th Int. Seminar on„Aluminium extrusion technology‟, Chicago,
101 – 106; 1996,Washington, DC, TheAluminium Association.
[12]. l. anand: Comput. Mech., 1993, 12, 197 – 213.
[13]. l. anandand w. tong: Ann. CIRP, 1993, 42, 361 – 366.
[14]. m. p. clodeand t. sheppard: Mater. Sci. Technol., 1990, 6,755 – 763.](https://image.slidesharecdn.com/a1160103-150807072108-lva1-app6891/85/Extrusion-process-and-parameters-involved-in-the-experimental-and-numerical-investigation-review-3-320.jpg)
Extrusion process and parameters involved in the experimental and numerical investigation-review
- 1. International Journal of Engineering Research and Development e-ISSN: 2278-067X, p-ISSN: 2278-800X, www.ijerd.com Volume 11, Issue 06 (June 2015), PP.01-03 1 Extrusion process and parameters involved in the experimental and numerical investigation-review Sangamesh Sirsgi1 , Dr. Shrishail Kakkeri2 , Nagraj Patil3 Asst. Professor and HOD, Department of Mechanical, LAEC, Bidar1 Professor and HOD, Department of Mechanical, SVCE, Bangalore2 Asst. Professor SET, Jain University, Bangalore3 Abstract:- With the conventional extrusion process it is very difficult to produce a hollow section tubes, for various types of Aluminium Alloys, such as Al6061, Al6063 & Al7075. Because of complicated structure of die Assembly it is became mandatory to investigate experimentally. For 6061 Al alloy Taguchi Method is applied to optimize the parameters involved in it. For other materials Numerical Analysis is carried out for investigation of various parameters. In this review paper the discussion is carried out for Al6061,Al6063& Al7075 materials in the extrusion process for investigating the different process parameters by Taguchi & Numerical Analysis Method. I. INTRODUCTION Extrusion appears to be a means of breaking down as cast structure of billet being subjected to only compressive forces in the extrusion process. In the cold extrusion, punches and dies are made up of wear resistant tool steels such as high alloy chromium steels which are subjected to severe working conditions in order to report dimensional stability and good surface finish. Cold extrusion models to verify parameters that influence the process have been investigated. Qamar [3], through a Finite Element Method (FEM) studied extrusion complexities and dead metal zone using numerical simulations extrusion to validate experimental observations. Dies of three different profiles made of H13 steel were used on lead and Al- 6063 alloy. Fluctuations in metal distortion during plastic flow and dead metal zone size were observed. This shows the variation in die profile symmetry and extrusion ratio. Tiernan used two different lubricants namely zinc stearate and oil based lubricant containing lead and copper additives. The experiment was configured to analyze effects on the reduction ratio die angle and die length on the extrusion force. Data obtained from experimental result and by computations using FEM predictive simulations were compared. The highest extrusion force obtained by experiment. The force was measured when extruding the aluminum billet using a die with exit diameter, die angle, and land height. In comparison of results, reasonable correlations were observed to exist between FEM and experimental values of extrusion forces[1]. Aluminum extrusion is a single pass process to produce a long part with high accuracy and complex cross sectional geometry. The only way to vary the cross section is by the use of extrusion die. A solid cylindrical billet is heated and placed inside a container which is pushed by hydraulic punch is forced to flow through die set. Therefore, products with varied cross sections such as rods, wires, sheets, tubes, hollow or non- hollow parts can be fabricated [1]. In recent years, there are many researches analyzing plastic deformations as well as die wear by finite element analysis[2].The basic process of extrusion is well described as a thermo- mechanical event in a quite recent text which indicates that the mathematical description of the process is still largely semi-empirical. The extrusion process is complex and involving interaction between the process variables and the material‟s high temp properties. Theoretically the variables that can be controlled are the extrusion ratio, the ram speed, and the initial extrusion temperature. However, events on the micromechanical scale are still not sufficiently described. The most important of all these is possibly the mechanics at the interface between tooling and material. This influences the analyses of the temperature changes occurring during the process, the temperature and the temperature history determining the structure of the extruded and hence, to a large extent, its properties.[3] II. LITERATRE REVIEW S. O. Adeosun et al [1] Have made an investigation of die entry angles 15o , 30o , 45o ,60o ,75o & 90o were simulated. Improvement is observed with 45o , 90o & 75o die entry angles. It is been observed that at 45o die entry angle the index of 2.1 for plain carbon steel die & 1.8 for steel die. Quang-Cherng Hsu et al [2] Have investigated for Al7075 square tube with both simulation & experiment. In this there are several factors which are taken for simulation & experiment are billet temperature, billet
- 2. Extrusion process and parameters involved in the experimental and numerical investigation: review 2 dimensions, flow stresses, die cavity & product geometry. The material Al7075 behaves high forming resistant when compared to Al6063 & Al6061. Flitta et al[3] This investigation is mainly focuses on simulation of the extrusion process & in particular the effect of the initial billet temperature on friction & its consequences on material. The simulation is validated with experimental results. The effect of billet temperature both in simulation & experimentally are presented. Rajamamundi Prabhu et al [4] Have gone through the forming of hollow section tubes that are very difficult to produce by conventional extrusion with a mandrel on the stem. During the hot extrusion for Al6061 Alloy the change of process parameters will effect to the mechanical properties. In this extrusion are tested for tensile test, flattening test, expanding test using a conical punch, surface finish & micro-structure. III. EXTRUSION PROCESS FOR ALUMINUMALLOY A. Extrusion Process This study uses direct extrusion or forward extrusion. The process is that when the billet is pushed in the container, the ram keeps pushing forward, and then the material is extruded and flows out of the die outlet. As the material flows out in the same direction as the ram moves, when the billet is about 20mm thick, the extrusion stops, while the ram moves backward, another billet is put into the container, and then the ram presses in the new billet. The process is then repeated, as shown in Figure. [2] IV. FRICTION The coefficient of friction at the metal billet interface contributes significantly to the difficulty of extruding, and it is a point where the friction resistance approaches the shear resistance of the hot material during the deformation. Furthermore it is a point where a fraction or all of the displacement of billet at the interface occur by shear in its surface layers leaving a fragment of the billet deposited on the wall of the container. In practice aluminium alloys are extruded without any lubricant or with only a small amount of graphite applied to the die face. Finding a suitable lubricant would be adifficult task and in any case of un- lubricated aluminium extrusion is desirable in order to prevent impurity pick up from the tools and to ensure that all the material making up the extruded surfaces originates from material within the billet. Therefore the interfacial conditions at the billet container interface during extrusion has a direct effect on metal the stresses acting upon both the tools and within the material and hence load and energy requirements and extruded temperature. V. SELECTION OF CONTROL FACTORS The objective of the present work is to identify the effect of convex die angle which would optimize the load and tensile strength of hot extruded tubes. The process parameters generally considered for hot extrusion process of Al 6061 alloy tubes using port hole die method include extrusion speed, die shape, billet temperature, mandrel length, convex angle, tooling temperature, extrusion ratio, port hole number and mandrel shape etc. In Taguchi method, the selection of influential parameters for analysis is a critical issue. For the present case, the most influential process parameters for the analysis are selected based on studies reported in literature with main focus on tensile strength and load characteristics and they are listed. These four input parameters are taken as
- 3. Extrusion process and parameters involved in the experimental and numerical investigation: review 3 control factors and each factor has been considered with three levels. Since the number of degrees of freedom is 8, an orthogonal array (inner array) L 9 has been found suitable for the present design.[4] VI. CONCLUSIONS 1) In this extrusion process the thickness of the product is varied and other parameters are kept remain same. 2) If we consider billet dimension for fixed condition, we get smaller extrusion ratio for thicker product & also smaller stress in the die. 3) With the numerical analysis the maximum stress is on corners of the square tube which is same for the experimental method. REFERENCES [1]. O.P. GbeneboroSekunowO.I. , S. O. Adeosun, Effect of Die Entry Angle on Extrusion Responses of Aluminum 6063 Alloy International Journal of Engineering and Technology Volume 4 No. 2, February, 2014 [2]. Quang-Cherng Hsu, Kun-Hong Kuo, Ping-HsunTsai Square Tube Manufacturing for Al7075 by Forward Extrusion with Porthole Die [3]. I. Flitta and T. Sheppard Nature of friction in extrusion process and its effect on material, Manuscript received 15 May 2002; accepted 16 December 2002.# 2003 • [4]. RajamamundiPrabhu 1 and V.S. K. Venkatachalapathy “EFFECT OF CONVEX DIE ANGLE OF PORTHOLE DIE ON PLASTIC DEFORMATION AND EXTRUSION PROCESS IN TUBE EXTRUSION”ARPN Journal of Engineering and Applied Sciences, VOL. 5, NO. 12, DECEMBER 2010 [5]. flittaand t. sheppard: Proc. 7th Int. Seminar onAluminium extrusion technology‟ Chicago, 197 – 203; 2000,Washington, DC, TheAluminium Association. [6]. flittaand t. sheppard: Proc. 5th Int. ESAFORM Conf.,Krakow, Poland, April 2002, European Scienti.c Associationfor Material Forming, 435 – 438. [7]. chanda, j. zhou, l. kowalsiand j. duszczyk: Sci. Mater.,1999, 41, 195 – 202. [8]. j. e. van rens, w. a. m. brelemansand f. p. t. baajens:Proc. 7th Int. Seminar on „Aluminium extrusion technology‟,Chicago, 99 – 107; 2000, Washington, DC, TheAluminiumAssociation. [9]. a. dean and z. m. hu: Proc. 6th Int. Conf. on „Technologyof plasticity‟, Nuremburg, Germany, September 1999, Vol. 1,541 – 550; Springer – Verlag. [10]. s. abtahi, t. weloand s. storen: Proc. 6th Int. Seminar onAluminium extrusion technology‟, Chicago, 125 – 131; 1996,Washington, DC, TheAluminium Association. [11]. t. welo, t. s. abtahiand i. skauvik: Proc. 6th Int. Seminar on„Aluminium extrusion technology‟, Chicago, 101 – 106; 1996,Washington, DC, TheAluminium Association. [12]. l. anand: Comput. Mech., 1993, 12, 197 – 213. [13]. l. anandand w. tong: Ann. CIRP, 1993, 42, 361 – 366. [14]. m. p. clodeand t. sheppard: Mater. Sci. Technol., 1990, 6,755 – 763.