Investigation Of Hot Deformation Behavior Of C60800 Aluminum Bronze Alloy Through Multi-Profile Die Extrusion With Parametric Optimization

Abstract

Aluminum Bronze Alloy Is One Of The Most Promising Engineering Materials For Marine, Automotive And Aerospace Application. Due To Its Corrosion Resistance, Good Hardness And Compression Strength. However, There Is Still A Need For Various Strength Enhancements To Meet Specific And General Application. Among Different Metal Forming Technique: Extrusion Is The Easiest And Most Promising Technique For Enhancement Of Mechanical Property. This Study Aimed To Investigate And Obtain Enhanced Mechanical Properties C60800 Aluminum Bronze Alloy By Determined The Required Load Analytically And Optimizing Process Parameters Of Numerical Analysis Of Hot Extrusion With A Multi-Profile Die (Cosine, Linear Convergent And Streamline) In Order To Determine Hot Deformation Behaviour (Damage, Z Load, Effective Strain)And Experimental Investigation With Optimum Parameters. Numerical Simulation Of Hot Extrusion Was Conducted By Finite Element Analysis Tool (Deform 3d) In Taguchi L9Orthogonal Array With Three Factors And Levels At Different Extrusion Ratios (2, 3, And 4), Ram Speeds (1, 2, And 3 Mm/S), And Die Length (10,20, And 30mm). Extrusion Load, Damage And Effective Strain Percentage Were Assessed And Analyzed Characteristics Of Single Response Using Taguchi's S/N Ratio And Anova. Based On Mathematical Modeling, Multi Response Optimization Of Process Parameters For Optimal Value Of Output Were Carried Out By Genetic Algorithm. The Fabrication Of Extrusion Dies And Container Carried Out At Optimized Parameters. At Optimized Process Parameters The Billet Material Of C60800 Extruded In All Types Of Die Profile By Using A Hydraulic Press Machine. Testing And Characterization Of Both Commercial Material And Extruded Product Was Conducted Using Mechanical And Metallurgical Testing Machines. Finding Obtained After Extrusion Shows That Hardness Values Were Improved By 18%, 17.5% &16% And Compression Strength Also Increased By 11%,9.5% & 8% For Cosine, Streamline And Linear Convergent Die Profile Respectively. Results Obtained From An Optical Microscope Showed That Refined Grain Micro structure For Extruded Samples. Corrosion Rate Of Linear Convergent And Streamline Die Extruded Sample Are Higher Than Cosine Die Profile But Much Lower Than Commercial Sample. This Research Work Is Expected To Help All Industries And Researchers Working In This Area Of Focus