Process Simulation of Friction Extrusion of Aluminum alloys

The friction extrusion process (FEP) 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 FEP is the non-equilibrium thermo-mechanical condition created at the contact region between the die and billet, leading to a possibly improved microstructure. Numerical simulations of FEP are highly complex due to contact between the tool and the workpiece, and 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, strain and velocity distributions illustrate the effect of extrusion ratio on the deformation characteristics of the extruded aluminum alloys, thereby assisting in experimental microstructure interpretation.