The Effect of the Extrusion Ratio on Load and Die Wear in the Extrusion Process

In this paper, regarding the example of concurrent extrusion of a round bar, the results of a comparative analysis of the impact of the extrusion ratio R on process parameters such as die wear intensity, extrusion force, stress intensity in the die, and its elastic deformation during extrusion are presented. The tests were carried out in a wide range of the R (1.5–11), assuming a constant outer diameter of the die. A comparative analysis of the wear was carried out in the area of the die corner radius and the calibration strip since the wear is the highest there. Based on the result obtained, it was shown that the increase in the extrusion force was not proportional to the increase in the extrusion ratio, and this could be described by a logarithmic equation. On the other hand, the value of equivalent stresses in the area of the die corner depends, to a relatively small extent, on the value of the extrusion ratio. However, due to the deformation of the die, it is most advantageous to use an extrusion ratio greater than or equal to three. Based on the wear analysis, it was estimated that the increase in the extrusion ratio R from 3 to 7 caused a more than 2.5 times increase in tool wear. In turn, the implementation of the extrusion process with the use of R = 11 caused a 4.5-fold increase in the average depth of die wear compared to its wear using the extrusion ratio R = 3