Numerical and Response Surface Interactions for Optimizing Extrusion Parameters

Abstract: An experimental program was undertaken to extrude a lead alloy on ELECompact-1500 compression machine. Extrusion variables were extrude diameter (d), die bearing length (h), and included die entrant angle Ө = 90 o. Using experimental values, numerical models were obtained to describe the relationship between extrusion variables and extrusion pressure and extrude deflection. The numerical models were then used to obtain the response pressure predictions for aluminum alloy. Results of validation tests indicated good correlation between predicted and experimental values. The predictions also compare favorably with values obtained by a similar second-order modified upper bound model frequently used in industry for estimating extrusion loads with prediction errors below 4%. Surface responses graphs of extrusion pressure and extrude deflection were also used to define the optimized field for interaction of extrusion parameters for minimizing extrusion loads and controlling extrudes deflection or bending. Owing to fewer input variables, the proposed models were considered convenient options for a quick estimate of extrusion loads and product curvature