FEM modeling of micro-extrusion of square section from Al 6063 round bar using cosine die profile

Abstract

Extrusion plays an important role in manufacture of micro-product with better mechanical property and surface integrity. Micro-products are used in different applications such as aerospace, bio-medical, nuclear, automotive and defense sector. Though a number of micro-machining methods are available for fabrication of micro products, manufacturing micro-products is very important from the enhancement of mechanical strength, surface integrity and reduction of wastage of material. Al-6063 alloy is an important material used in different application because of its specific strength and better formability. Die profile plays an important role in the process of micro-extrusion in terms of improvement of product quality. Converging non-linear die profile is very useful for gradual deformation and reduction in extrusion load. In the present investigation, FEM simulations for micro-extrusion has been carried out for extrusion of square section from Al-6063 round bar using cosine die profile. The diameter of billet is taken as 1mm. Extruded products are made using 50%, 70% and 90% reduction. Extrusion load, effective stress, effective strain and temperature have been determined.