Investigation On Deformation Behaviors Of Non-Ferrous Alloys Through Continuous Forming Extrusion

Abstract

Determining The Optimal Input Process Parameters Of Conform Extrusion (Ce) To Manufacture A Non-Ferrous Material Is Critical To Produce Better Products. This Could Be Not Only From Cost Perspective But Also Strength Aspects. The Main Objectives Of This Study Were To Investigate The Effects Of Ce Input Parameters On Responses Such As Extrusion Load, Effective Stress And Damage, The Microstructure And Mechanical Properties Of The Extrudates. The Ce Input Variables Explored In This Investigation Were Extrusion Wheel Speed, Feedstock Temperature, Die Temperature, Friction Factors And Extrusion Ratio. The Materials Considered For This Research Were Aluminum (Aa1100), Copper (C101) And Copper-Chromium-Zirconium (C18150) Alloy. Analytical, Computational And Experimental Methodologies Were Employed To Explore And Validate The Obtained Results. In The Analytical Investigation, Upper Bound Methodology (Ubm) Was Applied To Estimate An Optimal Load Requirement. Deform 3d Analysis Tool Was Used For Simulations And Explorations Of Extrusion Load, Effective Stress, And Damage Responses. Computational Results Were Further Analyzed And Optimized Through Response Surface Methodology (Rsm). The Same Results Also Mathematically Modeled Through Second Order Regression Model And The Model Accuracies Were Also Validated Using Anova. R2Values Through Rsm And Artificial Neural Network (Ann)?? Genetic Algorithms (Ga) Compared. In The Comparison, The Better Values Were Seen Through Ann-Ga. Experiments Were Performed Using A Commercial Setup Of A Tbj 350 Conform Extrusion Machine Taking Optimized Input Process Parameters Obtained From Rsm And Ann-Ga. Regarding Optimal Load Obtained Through Ubm, It Became In Good Agreement With Computational And Experimental Ones. The Feedstock And Ce Extrudes Of Aa1100, C101 And C18150 Were Tested, And Characterized Through Microstructure And Mechanical Tests To Observe The Effects Of The CeParameters. The Ce Input Variables Effects On The Effective Stress, Damage, Microstructures, Tensile Strength, Percent Of Elongation, Hardness, And Wear Characteristics Of The Extrudate With Respect To Feed-Metal Were Investigated. It Was Observed That The Microstructures Of The Extrudates Were Refined. Significant Improvements In Percent Of Elongation And Tensile Strength Were Obtained In All Three Extrudates (Aa1100, C101 And C18150). Similar Improvements Also Imparted In Hardness And Wear Characteristics Of The Extrudates. Optimal Ce Parameters For Least Effective Stress And Damage Also Identified. The Findings Are Expected To Meet The Requirements Of Industries, Designers, Researchers And Other Community Working In These Fields.