Fabrication Of Hexagonal Bar From Aluminum Alloyaa6063scrap By Frictional Stir Back Extrusion On Milling Machine

Abstract

Friction Stir Back Extrusion (Fsbe) Is A Novel And An Efficient Method Of Manufacturing Sounded Products By Using Specialized Tool In One Step (Without Melting Of Scrap). It Can Be Saved About 40% Of Material, 26-31% Of Energy Consumption, And 16-60% Of Labor Costs Compared With Conventional Extrusion. The Objective Of This Research Was To Fabricate A Hexagonal Bar From Aluminum Alloy Scrap By Fsbe. The Material Used For This Study Was Aa6063 As A Scrap And H13 Tool Steel As A Die. The Sampling Method Is, Simply Extruded Out The Hexagonal Shaped Bar At The Center Of Die Hole By Using Friction Formed Between Scrap Die Interface. The Depth Of Extrusion Land To Form A Shape Of Sample Bar Was 2mm. After 2mm, The Diameter Of Die Hole Increased Into 14mm In Order To Decrease The Friction Force Between Hole Of Die And Bar Surface. The Length Of Extruded Sample Was 260mm, 100mm, 70mm, 210mm, And 270mm (From 630rpm To 200rpm) And The Same 6mm Inscribed Diameter Thickness. The Considered Parameters Were Chamber Rotational Speed And Vertical Die Transverse Speed As Major Parameter. Aluminum Hexagonal Shaped Bar Is Used As A Supporter In Medical And Marine Industry, As A Raw Material To The Mass Production Of Hexagonal Head Aluminum Nut And Bolt, Allen Wrenches Etc. The Microstructural Investigation Was Performed By Using Optical Microscopy. Extruded Bar Was Defect Free, Non-Blurred Grain Boundary And Clear Surface Than The Base Material. The Hardness And Compression Test Were Done By Using Vickers Hardness Tester And Universal Testing Machine (Utm). The Hardness Value Of Base Material Is Less Than The Sample Extruded At 200, 400 And 500rpm And Also Greater Than The Other Extrudes. The Result Showed That The Compression Strength Of Extruded Sample Was Higher Than The Base Material By 5%. This Work Has Proved The Feasibility To Extrude Hexagonal-Shaped Bar By Using Fsbe By Fixed Die And Rotated Chamber. The Optimum Rotational Speed Of Chamber To Produce Sample Bar With The Minimum Twist Angle Is 250rpm And Transverse Speed 6.25mm/Min. If The Rotational Speed Increases Twist Angle Also Increased.