Extrusion of Aluminum 1100

Abstract

A laboratory-scale extrusion capability facilitates parametric study of metal extrusion processes. Commercial simulation code, HyperXtrude, was used to simulate laboratory experiments performed using a flat-die. In the experiments, Ram velocity and billet temperature were the process parameters that were controlled. Simulation model was validated by comparing the results with experimentally obtained load and temperature histories on tooling. The results of simulation and experiments were found to be in good agreement. ‘Optimized’ values for friction and convection film-coefficient were used to reach the best fit. The breakthrough load is predicted with good accuracy; however, the accuracy in load correlation is not sustained throughout the process duration as predicted load trend deviates from experimental data towards the end of the ram stroke. The aim of this work is to benchmark a commercial extrusion simulation code for a range of profiles.

Experimental setup

A 1.25 inch diameter flat die was machined with a bearing diameter of 0.25 inches for extruding 1 inch length billet with an extrusion ratio of 25. An Instron 8850 multi-axial test center was adapted for extrusion experiments by machining the four components; Chamber, Sleeve, Die and a rigid base to support the die. These parts were assembled to form the extrusion fixture.