Lab-Scale Extrusion

Introduction

A laboratory-scale extrusion capability was developed at the Center for Advanced Vehicular Systems (Ms State U) to extrude billets of upto 1.5" length and 1.25" diameter using various die configurations ranging from simple circular solid profile to hollow pipe profile. An existing Instron 8850 test center was adapted for this purpose. Load at billet-die interface was recorded by a load cell while temperature on tooling components was measured by 4 K-type thermocouples - two each on sleeve and die.

Test setup

A schematic of the fixture is shown below.

Schematic of the laboratory-scale extrusion fixture

Die geometries

Flat die

Conical die

Test Matrix

Test Matrix for AZ61 billets

Test Name	AZ61 Billet Configuration	Extrusion Ratio	Billet Temperature (deg. C)	Ram Velocity (mm/min.)	Die Type	Bearing diameter (inches)
Test 1	Cylindrical	6.25	460	5	Conical	0.5
Test 2	Cylindrical with pocket	6.25	460	5	Conical	0.5

Test Matrix for AM30 billets

Test Name	Extrusion Ratio	Billet Temperature (deg. C)	Ram Velocity (mm/min.)	Die Type	Bearing diameter (inches)
AM30_Test-1	25	455	5	Flat die	0.25
AM30_Test-2	25	455	10	Flat die	0.25
AM30_Test-3	25	455	15	Flat die	0.25
AM30_Test-4	25	455	20	Flat die	0.25
AM30_Test-5	25	455	30	Flat die	0.25

Results

The load and temperature histories recorded in the experimental trials are presented below for AZ61 and AM30 billets.

Experimental load and temperature history obtained from AZ61 extrusion experiments

Experimental load and temperature history obtained from AM30 extrusion experiments