Abstract
Aluminium based matrix composites with boron carbide as particle reinforcement called Discontinuous reinforced metal matrix composites (DRMMs) possess high specific strength, high elastic modulus, good wear resistance, damping capacity and thermal stability. But during the development of DRMM composites, compression process like extrusion is an advisable secondary process for homogenous structure. This research work investigates the metal flow behavior of Al-B4C based DRMM composite through six different die profiles namely third order polynomial, fourth order polynomial, cosine, elliptical, hyperbolic and conical geometry. Extrusion load, stress and strain distribution, and metal flow for above said die profiles are predicted by using analytical approach upper bound technique and compared with finite element method. Cosine and third order polynomial profiles are found to be most optimal in terms of homogenous and minimal extrusion load requirement. To validate the results, specially made Al-B4C composite through stir casting route was extruded from round to hexagon through an exclusively fabricated cosine die. Results observed from the experiment have good agreement with both analytical and numerical.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
R. Narayanasamy, R. Ponnalugusamy, R. Venkatesan and P. Srinivasan, An upper bound solution to extrusion of circular billet to circular shape through cosine dies, International Journal of Materials & Design, 27 (2006) 411–415.
R. Narayanasamy, R. Ponnalugusamy and P. Srinivasan, Design and development of stream lined extrusion dies a Bezier curve approach, International Journal of Materials Processing echnology, 161 (2005) 375–380.
N. Venkatareddy, P. M. Dixit and G. K. Lal, Die design for axisymmetric extrusion, International Journal of Materials Processing Technology, 55 (1995) 331–339.
Joseph S. Ajiboye, Upper bound analysis of extrusion from square billet through circular and square / rectangular dies, Journal of Mechanical Science and Technology, 23 (2009) 461–474.
S. Ajiboye and M. B. Adeyemi, The effect of selected parameters on temperature distribution in axisymmetric extrusion process, Journal of Mechanical Science and Technology, 21 (2007) 1553–1559.
Y. H. Seo and C. G. Kang. Effects of hot extrusion through a curved die on the on the mechanical properties of SiC/Al composites fabricated by melt-stirring, Journal of Composites Science and Technology, 1999 (643–654).
E. Mohammad Sharifi, F. Karimzadeh and M. H. Enayat, Fabrication and evaluation of mechanical and tribological properties of boron carbide reinforced nanocomposites, Materials & Design, 32 (6) June (2011) 3263–3271.
E. M. Herba and H. J. McQueen, Influence of particulate reinforcements on 6061 materials in extrusion modelling, Journal of Materails Science and Engineering, A 372 (2004) 1–14.
Fehmi Nair and M. Baki Karamis, An investigation of the tribological interaction between die damage and billet deformation during MMC extrusion, Tribology International, 43 (2010) 347–355.
M. Schikorra, L. Donati, L. Tomesani and A. E. Tekkaya, Microstructure analysis of aluminium extrusion: grain size distribution in AA6060, AA6082, AA6075 alloys, Journal of Mechanical Science and Technology, 21 (2007) 1445–1451.
B. P. P. A. Gouveia, J. M. C. Rodrigues, N. Bay and P. A. F. Martins, Deformation analysis of the round to square extrusion: a numerical and experimental investigation, Journal of Finite Elements in Analysis and Design, 35 (2000) 269–282.
C. Venkatesh and R. Venkatesan, Design and analysis of stream lined extrusion die for round to hexagon through Area mapping technique, Upper bound technique and Finite element method, Journal of Mechanical Science and Technology, 28 (5) (2014) 1–8.
Metal Forming: Processes and Analysis-B, Avitzur, McGraw Hill, Newyork.
Nanoindentation- Anthony C. Fischer- Cripps, Springer.
DEFORM-3D V6.1-Manual.
Author information
Authors and Affiliations
Corresponding author
Additional information
Recommended by Associate Editor Dae-Cheol Ko
C. Venkatesh received his A. M. I. E in Institution of Engineers (India), M.E. degree in Anna University of Technology, Coimbatore with Gold Medal. Now He is pursuing his Ph.D. Mechanical Engineering in Anna University, Chennai. Mr. C. Venkatesh is a Assistant Professor in Jansons Institute of Technology, Coimbatore. His research interests include die design for extrusion of Discontinuous Reinforced Metal Matrix Composite, investigation of effect of friction in metal forming, and nano composite coating over the die surface.
R. Venkatesan received his B.E. degree in Madras University, M.E. degree in Government College of Technology, Coimbatore and Ph.D. in National Institute of Technology, Trichy. Dr. R. Venkatesan is currently a Professor and Head of the Department of Mechanical Engineering, Sona College of Technology, Salem. His research interest includes metal forming techniques, Extrusion process and CAD/CAM.
Rights and permissions
About this article
Cite this article
Venkatesan, R., Venaktesh, C. Analytical, numerical and experimental approach for design and development of optimal die profile for the cold extrusion of B4C DRMM Al 6061 composite billet into hexagonal section. J Mech Sci Technol 28, 5117–5127 (2014). https://doi.org/10.1007/s12206-014-1134-y
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12206-014-1134-y