Numerical and experimental investigations on AA6063 extrudates: effect of number of portholes on extrusion load and weld strength

Abstract In aluminium extrusion process, metal flow is greatly controlled by the die geometry and a variety of intricate profiles can be achieved by designing dies of different configurations. In porthole die extrusion, number of portholes used for a profile is often determined by the subjective knowledge of designers. Nevertheless, extrusion load and weld strength of profile produced are not only dependent on extrusion ratio, temperature of deformation but also on the number of portholes along with other die geometry variables. In the present investigation, systematic studies were carried out on three different dies with four ports, three and two ports around die center to extrude profiles of outer diameter 29.4 mm and thickness 2 mm. Numerical simulations were carried out for estimation of pressure, temperature, strain, and strain rate parameters in the weld chamber for all the dies, followed by press trials and profiles produced were subjected to wedge expansion test. The results from numerical simulations indicated that pressure generated inside weld chamber increases with number of portholes. The surface plots indicated highest pressure of about 280 MPa for four port hole and about 276 MPa for three ports die and pressure of about 160 MPa was estimated for two port hole die at the entry of weld chamber , which is 65 mm from profile end. Similarly, temperature at profile exit was 551 °C for four portholes die and 546 °C for three portholes die and 537 °C for two portholes die. Furthermore, press trials indicated peak extrusion loads of 5241 kN, 4406 kN and 3961 kN respectively for four, three and two portholes die. Thus, the peak extrusion load decreased by about 16% for three port and about 25% for two ports die in comparison with four port die. Also, the extruded profiles in wedge expansion test indicated mean compression load of 22.70 ± 0.14 kN in four porthole die, mean compression load 22.29 ± 0.26 kN for three port die and mean compression load of 17.841 ± 0.27 kN.