Process Parameter Investigations of Backward Extrusion for Various Aluminum Shaped Section Tubes Using FEM Analysis

In this article, a FEM investigation has been carried out to analyze the backward extrusion of aluminum tubes which have internally and externally shaped sections. ABAQUS/Explicit finite element method was used to solve the problem. As a result, the distribution of stress, strain, and spatial velocity in the deformation region were obtained. Grid deformation patterns were also studied using the FE simulation to observe the material flow during the process. Initial billets with various cross sections such as rectangular, elliptical, hexagonal, octagonal, and square shapes were utilized in the simulations. Also various shaped punches such as circular and elliptical sections were employed for this analysis. In this article, the influence of the process parameters such as friction factor and reduction in area on the extrusion pressure was studied. The effects of reduction of area and friction factor on the configuration of free surface and velocity field have been investigated too. The results obtained from the present study were compared with analytical and experimental works and acceptable agreements were observed.