Direct extrusion process analysis with proposed numerical modeling improvements - product quality, process parameters, and microstructure prediction

A numerical modeling and simulation analysis was performed on the hot-direct extrusion process with the finite element modeling (FEM) software package, DEFORM(TM) 3-D for three case studies. The research demonstrated that a commercially available, industry-accepted numerical simulation software package can predict the material response and microstructure development with simple simulated state variables (i.e. strain, strain rate, and temperature) and easily measured initial material characteristics (e.g. grain diameter). The predicted state variables provided insight into sources for limited extrudate quality, aided in processing improvements, and were the primary variables used to predict material response. The analysis began with studying the influence of tool misalignment and the degree of billet upset on extrudate dimensional quality, measured in terms of tube eccentricity, for a copper tube case study. Under ideal upset and tool alignment conditions, the simulated eccentricity was minimized. If the mandrel had a misalignment that was within tolerance, the eccentricity initially was minor in comparison to the eccentricity produced toward the end of extrusion. Consequently, through the use of DEFORM(TM) 3-D the extrusion mechanics were understood and sources for tube eccentricity were identified. In the second case study, a flow stress model was developed as a function of the state variables for an as-cast homogenized magnesium alloy. The modeled flow stress curve reasonably agreed with experimental compression flow stress data. The model was then implemented into DEFORM(TM) 3-D to utilize the simulated state variables to examine the extrusion of an automobile structural component. It was concluded that once the initial material characteristics are accounted for in the flow stress model it will more accurately and efficiently predict the flow stress response for the actual material being considered than a generic experimental flow stress-based material library entry in DEFORM(TM) 3-D. The third case study assessed an aluminum alloy's microstructure response to hot-direct extrusion processing conditions. The DEFORM(TM) 3-D simulated state variables were incorporated into a dynamic recrystallization (DRX) model that with reasonable accuracy predicted the surface grain structure evolution when compared to experimental results. By knowing the grain structure response the surface physical properties of the extrudate can be deduced.