Effect of Processing Parameters On Extrusion Using Experimentation With Modeling Materials and Simulation Techniques

Abstract

In this study, effects of extrusion parameters on extrusion have been studied newlineusing modeling material Plasticine as it behaves like a near ideal plastic material newlineand gives similar result as of hot rolling of metallic alloys like Aluminum alloy. newlineExtrusion parameters studied are ram speed, geometrical and modeling material newlineproperties. The methodology uses combining analytical methods, FEM simulations newlineand experiments with the modeling material to optimize the extrusion processing newlineparameters. Experiments have been carried out with semi conical dies of angle newline30°, 45° and 60° and the shapes taken were rod and tube at different ram speed. newlineAlso experiments were carried out with flat dies to extrude five shapes of circular, newlinetriangular, square, L section and I section. The extrusion were carried out at newlinedefferent ram speed and it was found that and high ram speed of 25mm/min. gives newlinegood quality of extrudate. Also the load varied for different geometries with same newlinereduction ratio R equal to 4. FEM alalysis carried out with aluminum alloy shows newlinesimilarity between the processing parameter of plasticine and actual material. As newlinethe otherwise finding out of optimized parameters with material will consume much newlinetime and resources. newlineThe present study shows the usefulness of combined approach of using mixed newlinetechniques of experimentation and simulations. Although the application of FEM newlinetechniques reduces the cost of experiments with real materials, it is costly and newlinerequire trained manpower to use it. Further the methodology goes one step further newlineand using ANN technique makes a system to predict the processing parameters newlinewithout having the FEM software at the end of the actual user. ANN application newlineII newlinetakes process inputs and gives the required output. In this study it has been newlinesuccessfully used to optimize Aluminum alloy extrusion process. newlineThe experiments carried out with modeling materials uses very inexpensive newlineexperimental setup and reduces to the time required for extrusion process newlineoptimization.