Experimental and numerical prediction of extrusion load at different lubricating conditions of aluminium 6063 alloy in backward cup extrusion

Abstract

In the present research work using a backward cup extrusion (BCE) die profile, different lubricating conditions on aluminum alloy AA6063 have been experimentally and numerically investigated to predict the extrusion load. It was obvious that due to an increase in applications of the extrusion process, many researchers have worked on the extrusion process using different methods to achieve their aims. This experiment was conducted with three different lubricants namely: Castor oil, Palm Oil and tropical coconut oil; as well as without lubricants. Different lubricating conditions were employed of varying strain rates ranges from 1.5×10-3s-1, 2.0×10-3s-1, 2.5×10-3s-1, and 3.0×10-3s-1; Numerical analysis and simulation for dry and lubricated conditions during extrusion load were also performed using DEFORM 3D software. The results show that prediction extrusion load increases with increasing strain rates. The maximum extrusion load was found to be higher for extrusion without lubricants. In all cases of strain rate, palm oil showed a lower extrusion load compared to the other lubricants. Castor oil indicated the highest extrusion load when the experiment was carried out using lubrication. There was a consistent agreement between the result gotten from the experiment and simulation results of the extrusion load-strike curve.