Process simulation of friction extrusion of aluminum alloys

Process simulation of friction extrusion of aluminum alloys

DIYOKE George, RATH Lars, CHAFLE Rupesh, BEN KHALIFA Noomane, KLUSEMANN Benjamin

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Abstract. The friction extrusion (FE) process is a solid-state material processing technique in which a translating extrusion die is pressed against a billet/feedstock material in a rotating extrusion container to produce an extruded rod or wire. A key aspect of FE is the generation of severe plastic deformation and frictional heat due to the relative rotation, leading to an improved microstructure. Numerical simulations of FE are highly complex due to contact between the tool and the workpiece, and the interplay between thermo-mechanical conditions and the present severe plastic deformation. In the present work, a three-dimensional finite element model is developed to study the material flow behavior for different extrusion ratios for a 60° die angle during friction extrusion. The developed model is numerically validated against experimental data. The spatial temperature and strain distributions illustrate the effect of extrusion ratio on the deformation characteristics of the extruded aluminum alloys, thereby assisting in understanding the material flow behavior.

Finite Element Method, Process Simulation, Solid-State Materials Processing, Friction Extrusion, Aluminium Alloy

Published online 4/19/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: DIYOKE George, RATH Lars, CHAFLE Rupesh, BEN KHALIFA Noomane, KLUSEMANN Benjamin, Process simulation of friction extrusion of aluminum alloys, Materials Research Proceedings, Vol. 28, pp 487-494, 2023


The article was published as article 53 of the book Material Forming

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