Finite Element Modeling of Ceramics Particles Reinforced Aluminum Alloy Composites under Forward Extrusion

Abstract

Finite Element Method (FEM) has becoming more influences in analyzing and solving metal forming problems from the beginning of punch and die designed up to setting the appropriated surrounding constrains in the deformation processes. This research was concerning about the study of simulation in cold forward bar extrusion of some aluminum alloys reinforced with ceramic particles using a commercial FE program; MSC. Marc to enhance the analysis. Two most important parameters in extrusion were investigated, which included area reduction ratio, εA, and die angle, 2∂, that affected to the forming force in the workpiece. In this research, the matrix part of composites studied was varied as follow: AA6061, AA6082 and AA230A reinforced by particles of SiC and Al2O3. Also, the volume fraction of reinforcement was another material parameter needed for the study. The dimension of initial billet in the simulation had 24.7 mm of diameter and 30 mm of length. The punch and die were assumed to be rigid which neglected the deformation. In case of heat dissipation, they were not considered in this simulation; therefore, the process assumed to be done isothermally at room temperature of 20°C. From the modeling results, the suitable conditions for different parameters were obtained, which assisted to the consideration of appropriated forward bar extrusion processes of such particulate reinforced Metal Matrix Composites (MMCs).