Deformations in the nonstationary stage of aluminum alloy rod extrusion process with a low elongation ratio

Abstract

Introduction. It is noted that extrusion is the main procurement process in the aluminum alloys forming operations. At the same time, the process has such a disadvantage as the nonstationarity of the metal plastic flow. The work aim is to establish the inhomogeneity deformation level of the pressed rod front part by numerical simulation using the finite element method. The study objectives are to formulate the extrusion process boundary conditions, to obtain a solution and to evaluate the inhomogeneity degree. Research methods: the finite element method was used to evaluate the deformed state. The actions sequence included the creation of primary deformation zone shape and the tool configuration. The mutual movement of the tool and the deformable material is set using the appropriate boundary conditions. The deformable medium is a ductile material with power-law hardening, the physical and mechanical properties correspond to the aluminum alloy of the 6000 series. Results and discussion: It is revealed that the strain degree in the pressed rod front part is extremely nonuniform distributed; differences above 300% are recorded. The strain degree distribution dependences in the rod cross sections are constructed depending on the distance from the front end at different relative radial coordinates. It is revealed that the rod central layers acquire a constant level of the strain degree earlier than the peripheral layers. The stationary process is achieved with less metal motion. The work result application scope is the technological study of rational metal cutting of aluminum alloys at the extrusion final stage in order to use recyclable waste more rationally. Conclusions. In the extrusion process with a low elongation ratio, the strain degree is distributed nonuniform both along the press rod cross and along its length. The rod front part remains weakly deformed both at the periphery and in the center in the nonstationary initial extrusion stage. It often forces to send for remelting due to the insufficiently developed metal structure. At the same time, if the limits on the minimum possible degree of deformation are set, then using the results of the calculation by the finite element method, the minimum length of the metal to be removed can be set, thereby reducing the mass of waste sent for remelting. © 2022 The Authors