Experimentation and Optimization Of Parameters In Aluminium 3003 Extrusion

Hot extrusion of aluminium 3003 alloy with u-shaped dies of similar entry and exit profiles (SEEP) is presented here. A laboratory extrusion rig was modelled and fabricated, aluminium 3003 alloys were prepared by sand casting method and extruded. Other existing dies start from circular shapes and gradually transform to the desired shape. However, dies with similar entry and exit profiles give products that are straight and deflection free thereby improving product quality. Experimental and simulation results were compared and the experimental values were found to be 10% higher, this is due to frictional effects and also billet velocity at the center being faster than at the edges. It is anticipated that implementing this innovative methodology will enhance the efficacy of the extrusion process, yielding products of superior consistency and quality. Response Surface method was utilized in the optimization and a positive correlation was found to exist between fillet radius, friction coefficient, billet length and extrusion force, while a negative correlation existed between billet temperature and extrusion force. Lastly, a model equation was developed to calculate the extrusion force which takes into cognizance the above mentioned parameters, the model had an R2 value of 0.77 indicating good accuracy.