Numerical and experimental investigation of central cavity formation in aluminum during forward extrusion process

• Published in: Journal of mechanical science and technology 2016, 30(5), , pp.1951-1956
• Main Authors: Hosseini, S. H., Sedighi, M., Mosayebnezhad, J.
• Format: Article
• Language: English
• Subjects: Aluminum; Coefficient of friction; Computer simulation; Control; Design optimization; Dynamical Systems; Engineering; Extrusion; Finite element method; Forward extrusion; Friction; Friction reduction; Industrial and Production Engineering; Mathematical analysis; Mathematical models; Mechanical Engineering; Reduction of area; Simulation; Taguchi methods; Vibration; Waste materials; Wastes; 기계공학
• ISSN: 1738-494X; 1976-3824
• DOI: 10.1007/s12206-015-1216-5

In the presented paper central cavity formation during the forward extrusion of commercially pure aluminum was investigated. For this purpose finite element analysis was utilized for simulation of this defect. The experimental tests were carried out on commercially pure aluminum. A good agreement between finite element simulations and experimental tests verified the adaptability of finite element simulations with the real process conditions. Taguchi method was performed for classifying the simulations regarding to consider synergistic parameters. The parameters include reduction of area, friction coefficient and die angle. Critical thickness, the representative waste material, was presented as a new criterion for optimizing the parametric study. By utilizing the Analyze Taguchi design , critical thickness was optimized and the effect of each parameter was recognized for different levels. In addition, the best levels with the minimum waste material were gained in which friction coefficient, die angle and reduction of area were 0.2, 5° and 20%, respectively. Also the amount of waste material was forecasted by just about 2% errors without FEA by Taguchi method.