Investigation of Cold Extrusion of Aluminum AA 2024 Alloy using Finite Element Analysis

In recent years, the interest in modeling extrusion processes has resulted in the development of several analytical and numerical methodologies. The present work optimizes cold extrusion process variables (Die angle (DA), Ram speed (RS), Coefficient of friction (CoF)) on extrusion force, displacemen...

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Bibliographic Details
Published inINCAS bulletin Vol. 14; no. 3; pp. 157 - 171
Main Authors KOTHASIRI, Anupama Francy, CHALAMALASETTI, Srinivasa Rao
Format Journal Article
LanguageEnglish
Published Bucharest INCAS - National Institute for Aerospace Research "Elie Carafoli" 09.09.2022
National Institute for Aerospace Research “Elie Carafoli” - INCAS
Subjects
Aircraft
Alloying elements
Aluminum base alloys
Coefficient of friction
Cold
Cold extrusion
Computer simulation
Damage
Deformation
deformtm -3d
Design
die angle
Extrusion dies
extrusion force and damage
Extrusion rate
Finite element analysis
Finite element method
Friction
Mathematical models
Mechanical properties
Optimization
Orthogonal arrays
Plastic deformation
Process variables
Rigid structures
Room temperature
Simulation
stress distribution
Tensile strength
Variables
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Summary:In recent years, the interest in modeling extrusion processes has resulted in the development of several analytical and numerical methodologies. The present work optimizes cold extrusion process variables (Die angle (DA), Ram speed (RS), Coefficient of friction (CoF)) on extrusion force, displacement, damage and time for the Aluminum AA 2024 alloy material. DEFORMTM-3D software is used to carry out numerical simulations and to study the behavior of the Aluminum AA 2024 billet during the plastic deformation over the conical die. The die/ container and ram (top die) are considered as rigid bodies and the room temperature is maintained during the extrusion process. The simulations are conducted as per L27 Taguchi orthogonal array. The obtained results are analyzed in ANOVA. An optimization using multiple variables is performed by grey relational analysis (GRA). The highest grey relational grade (GRG) is obtained for experiments conducted at DA level 2, RS level 2, and CoF level 3 (minimum extrusion force, damage and time) and (maximum displacement) is achieved by GRA. Systematically, the influence of the ram speed, coefficient of friction, and die angle are examined. The damage factor is considerable at 30° DA under the ram speed of 3mm/min.
ISSN:2066-8201
2247-4528
DOI:10.13111/2066-8201.2022.14.3.14