Process simulation of friction extrusion of aluminum alloys

George Diyoke; Lars Rath; Rupesh Chafle; Noomane Ben Khalifa; Benjamin Klusemann

doi:10.21741/9781644902479-53

Process simulation of friction extrusion of aluminum alloys

George Diyoke
, Lars Rath
, Rupesh Chafle
, Noomane Ben Khalifa
, Benjamin Klusemann

Helmholtz Centre Hereon

Research output: Contributions to collected editions/works › Article in conference proceedings › Research › peer-review

1 Citation (Scopus)

Abstract

The friction extrusion (FE) process is a solid-state material processing technique in which a translating extrusion die is pressed against a billet/feedstock material in a rotating extrusion container to produce an extruded rod or wire. A key aspect of FE is the generation of severe plastic deformation and frictional heat due to the relative rotation, leading to an improved microstructure. Numerical simulations of FE are highly complex due to contact between the tool and the workpiece, and the interplay between thermo-mechanical conditions and the present severe plastic deformation. In the present work, a three-dimensional finite element model is developed to study the material flow behavior for different extrusion ratios for a 60° die angle during friction extrusion. The developed model is numerically validated against experimental data. The spatial temperature and strain distributions illustrate the effect of extrusion ratio on the deformation characteristics of the extruded aluminum alloys, thereby assisting in understanding the material flow behavior.

Original language	English
Title of host publication	Material Forming : The 26th International ESAFORM Conference on Material Forming - ESAFORM 2023 - held in Kraków, Poland, April 19-21, 2023
Editors	Lukaz Madej, Mateuz Sitko, Konrad Perzynski
Number of pages	8
Volume	1
Place of Publication	Millersville
Publisher	MaterialsResearchForum LLC
Publication date	19.04.2023
Pages	487-494
ISBN (Print)	978-1-64490-246-2
ISBN (Electronic)	978-1-64490-247-9
DOIs	https://doi.org/10.21741/9781644902479-53
Publication status	Published - 19.04.2023
Event	26th International ESAFORM Conference on Material Forming 2023 - AGH University of Science and Technology, Kraków, Poland Duration: 19.04.2023 → 21.04.2023 Conference number: 26 https://esaform2023.agh.edu.pl/

Bibliographical note

Funding Information:
This project has received funding from the European Research Council (ERC) under the European Union’s Horizon 2020 research and innovation program (grant agreement No 101001567)

Publisher Copyright:
© 2023, Association of American Publishers. All rights reserved.

Research areas and keywords

Engineering
Finite Element Method
Process Simulation
Solid-State Materials Processing
Friction Extrusion
Aluminium Alloy

Access to Document

10.21741/9781644902479-53Licence: CC BY

Cite this

Diyoke, G., Rath, L., Chafle, R., Ben Khalifa, N., & Klusemann, B. (2023). Process simulation of friction extrusion of aluminum alloys. In L. Madej, M. Sitko, & K. Perzynski (Eds.), Material Forming: The 26th International ESAFORM Conference on Material Forming - ESAFORM 2023 - held in Kraków, Poland, April 19-21, 2023 (Vol. 1, pp. 487-494). (Materials Research Proceedings; Vol. 28). MaterialsResearchForum LLC. https://doi.org/10.21741/9781644902479-53

Diyoke, George ; Rath, Lars ; Chafle, Rupesh et al. / Process simulation of friction extrusion of aluminum alloys. Material Forming: The 26th International ESAFORM Conference on Material Forming - ESAFORM 2023 - held in Kraków, Poland, April 19-21, 2023. editor / Lukaz Madej ; Mateuz Sitko ; Konrad Perzynski. Vol. 1 Millersville : MaterialsResearchForum LLC, 2023. pp. 487-494 (Materials Research Proceedings).

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abstract = "The friction extrusion (FE) process is a solid-state material processing technique in which a translating extrusion die is pressed against a billet/feedstock material in a rotating extrusion container to produce an extruded rod or wire. A key aspect of FE is the generation of severe plastic deformation and frictional heat due to the relative rotation, leading to an improved microstructure. Numerical simulations of FE are highly complex due to contact between the tool and the workpiece, and the interplay between thermo-mechanical conditions and the present severe plastic deformation. In the present work, a three-dimensional finite element model is developed to study the material flow behavior for different extrusion ratios for a 60° die angle during friction extrusion. The developed model is numerically validated against experimental data. The spatial temperature and strain distributions illustrate the effect of extrusion ratio on the deformation characteristics of the extruded aluminum alloys, thereby assisting in understanding the material flow behavior.",

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note = "Funding Information: This project has received funding from the European Research Council (ERC) under the European Union{\textquoteright}s Horizon 2020 research and innovation program (grant agreement No 101001567) Publisher Copyright: {\textcopyright} 2023, Association of American Publishers. All rights reserved.; 26th International ESAFORM Conference on Material Forming 2023, ESAFORM 2023 ; Conference date: 19-04-2023 Through 21-04-2023",

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Diyoke, G, Rath, L, Chafle, R, Ben Khalifa, N & Klusemann, B 2023, Process simulation of friction extrusion of aluminum alloys. in L Madej, M Sitko & K Perzynski (eds), Material Forming: The 26th International ESAFORM Conference on Material Forming - ESAFORM 2023 - held in Kraków, Poland, April 19-21, 2023. vol. 1, Materials Research Proceedings, vol. 28, MaterialsResearchForum LLC, Millersville, pp. 487-494, 26th International ESAFORM Conference on Material Forming 2023, Kraków, Poland, 19.04.23. https://doi.org/10.21741/9781644902479-53

Process simulation of friction extrusion of aluminum alloys. / Diyoke, George; Rath, Lars; Chafle, Rupesh et al.
Material Forming: The 26th International ESAFORM Conference on Material Forming - ESAFORM 2023 - held in Kraków, Poland, April 19-21, 2023. ed. / Lukaz Madej; Mateuz Sitko; Konrad Perzynski. Vol. 1 Millersville: MaterialsResearchForum LLC, 2023. p. 487-494 (Materials Research Proceedings; Vol. 28).

Research output: Contributions to collected editions/works › Article in conference proceedings › Research › peer-review

TY - CHAP

T1 - Process simulation of friction extrusion of aluminum alloys

AU - Diyoke, George

AU - Rath, Lars

AU - Chafle, Rupesh

AU - Ben Khalifa, Noomane

AU - Klusemann, Benjamin

N1 - Conference code: 26

PY - 2023/4/19

Y1 - 2023/4/19

N2 - The friction extrusion (FE) process is a solid-state material processing technique in which a translating extrusion die is pressed against a billet/feedstock material in a rotating extrusion container to produce an extruded rod or wire. A key aspect of FE is the generation of severe plastic deformation and frictional heat due to the relative rotation, leading to an improved microstructure. Numerical simulations of FE are highly complex due to contact between the tool and the workpiece, and the interplay between thermo-mechanical conditions and the present severe plastic deformation. In the present work, a three-dimensional finite element model is developed to study the material flow behavior for different extrusion ratios for a 60° die angle during friction extrusion. The developed model is numerically validated against experimental data. The spatial temperature and strain distributions illustrate the effect of extrusion ratio on the deformation characteristics of the extruded aluminum alloys, thereby assisting in understanding the material flow behavior.

AB - The friction extrusion (FE) process is a solid-state material processing technique in which a translating extrusion die is pressed against a billet/feedstock material in a rotating extrusion container to produce an extruded rod or wire. A key aspect of FE is the generation of severe plastic deformation and frictional heat due to the relative rotation, leading to an improved microstructure. Numerical simulations of FE are highly complex due to contact between the tool and the workpiece, and the interplay between thermo-mechanical conditions and the present severe plastic deformation. In the present work, a three-dimensional finite element model is developed to study the material flow behavior for different extrusion ratios for a 60° die angle during friction extrusion. The developed model is numerically validated against experimental data. The spatial temperature and strain distributions illustrate the effect of extrusion ratio on the deformation characteristics of the extruded aluminum alloys, thereby assisting in understanding the material flow behavior.

KW - Engineering

KW - Finite Element Method

KW - Process Simulation

KW - Solid-State Materials Processing

KW - Friction Extrusion

KW - Aluminium Alloy

KW - Finite Element Method

KW - Process simulation

KW - Solid-State Materials Processing

KW - Friction extrusion

KW - alluminion alloy

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UR - https://www.mendeley.com/catalogue/e4fb6f9b-cfea-3b2d-ae9e-497833745244/

U2 - 10.21741/9781644902479-53

DO - 10.21741/9781644902479-53

M3 - Article in conference proceedings

SN - 978-1-64490-246-2

VL - 1

T3 - Materials Research Proceedings

SP - 487

EP - 494

BT - Material Forming

A2 - Madej, Lukaz

A2 - Sitko, Mateuz

A2 - Perzynski, Konrad

PB - MaterialsResearchForum LLC

CY - Millersville

T2 - 26th International ESAFORM Conference on Material Forming 2023

Y2 - 19 April 2023 through 21 April 2023

ER -

Diyoke G, Rath L, Chafle R, Ben Khalifa N , Klusemann B. Process simulation of friction extrusion of aluminum alloys. In Madej L, Sitko M, Perzynski K, editors, Material Forming: The 26th International ESAFORM Conference on Material Forming - ESAFORM 2023 - held in Kraków, Poland, April 19-21, 2023. Vol. 1. Millersville: MaterialsResearchForum LLC. 2023. p. 487-494. (Materials Research Proceedings). doi: 10.21741/9781644902479-53

Process simulation of friction extrusion of aluminum alloys

Abstract

Bibliographical note

Research areas and keywords

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