THE EFFECTS OF THE DIE HALF ANGLE OF TAPER DIE ON PLANE STRAIN EXTRUSION

2016 ◽  
Vol 78 (9-2) ◽  
Author(s):  
A. M. S. Zuan ◽  
S. Y. Yong ◽  
M. A. Nurul ◽  
S. Syahrullail ◽  
E. A. Rahim
Keyword(s):  
Surface Roughness ◽  
Relative Velocity ◽  
Palm Stearin ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Comparison Study ◽  
Taper Angle ◽  
Workpiece Surface ◽  
Half Angle ◽  
Taper Die

In this research, a study of the effect of a die half angle on the extrusion process has been performed. The experiments were conducted at room temperature around 27 °C. Two types of taper die with different die half angles (45° and 60°) were prepared. The test lubricants used were paraffinic mineral oil VG460 and Refined, Bleached and Deodorized (RBD) Palm stearin. The material of the workpiece (billet) was annealed with A1100 aluminium. The experimental results were focused on the extrusion load, tool and workpiece surface roughness and plastic deformation of the workpiece. The resultant relative velocity was calculated using a visioplasticity method. The results shows that a taper angle of 60° recorded higher resultant relative velocity with a lower extrusion load and surface roughness compare to the taper angle of 45°. The comparison study between Paraffinic Mineral Oil and RBD Palm Stearin shows no significant effect in both taper angles tested.

INVESTIGATION OF MICRO-PITS FORMATION ON BILLET SURFACES IN PLANE STRAIN EXTRUSION

2016 ◽  
Vol 78 (10-2) ◽  
Author(s):  
I. M. Izhan ◽  
S. Syahrullail ◽  
S. Y. Yong ◽  
M. A. Nurul
Keyword(s):  
Surface Roughness ◽  
Cross Section ◽  
Room Temperature ◽  
Palm Stearin ◽  
Mineral Oil ◽  
Tribological Performance ◽  
Work Piece ◽  
Half Angle ◽  
Plain Strain ◽  
Taper Die

Extrusion is a process of pushing a material through a die to yield a desired cross-section product. The application of surface texture has become well known for enhancing tribological performance. In this research, the effect of micro-pits embedded on a work piece lubricated with vegetable oil using plain strain extrusion were studied and compared with those seen with mineral-based oil lubricant. The experiments were conducted at room temperature (around 27℃). A taper die with a 60 die half-angle, with micro-pits array, was prepared. Test lubricants used were paraffinic mineral oil (PMO) VG460 and VG95 and refined, bleached and deodorized (RBD) palm stearin. The results were analysed to determine the extrusion load and the billet’s surface roughness and plastic deformation. RBD palm stearin was recorded as having the highest extrusion load (83.15 kN).

The Influences of the Die Half Angle of Taper Die During Cold Extrusion Process

2013 ◽  
Vol 38 (5) ◽  
pp. 1201-1207 ◽  
Author(s):  
S. Syahrullail ◽  
C. S. N. Azwadi ◽  
Y. M. Najib
Keyword(s):  
Extrusion Process ◽  
Cold Extrusion ◽  
Half Angle ◽  
Taper Die

Study of Alternative Lubricants for Cold Extrusion Process of A1100 Pure Aluminum

2014 ◽  
Vol 71 (2) ◽  
Author(s):  
A. Nurul M. ◽  
Syahrullail S.
Keyword(s):  
Renewable Resources ◽  
Pure Aluminum ◽  
Cold Work ◽  
Palm Kernel ◽  
Palm Stearin ◽  
Mineral Oil ◽  
Cold Extrusion ◽  
Film Material ◽  
Ability To Act ◽  
Taper Die

Lubrication in metal forming process is very important to control wear and friction at the interface between interacting surfaces. Non-renewable resources, such as mineral oil are widely used since a beginning due to its ability to act as a supplier to the wearing contact which functions as a film material or sustains chemical transformation to become a film material. Since it is will not last for a few more decades, renewable resources had been studied in order to find an alternative lubricant with presents similar results in terms of extrusion load and product quality. Two renewable lubricants were analyzed (Palm Kernel and Palm Stearin) together with additive free paraffinic mineral oil VG460 will act as a comparison lubricant. The experiment used a cold work plane strain extrusion apparatus consisting of a pair of taper die and a symmetrical work piece (billet). The billet material was annealed pure aluminum A1100 with radius of 5mm at the deformation area. It was found that palm Palm Kernel and Palm Stearin performed slightly high extrusion load, however they show no severe wear on product surface. Based on the results, it is proven that renewable based lubricants can be considered as a substitute to common mineral based lubricants used in the industry.

Effect of Surface Roughness of Pure Aluminium A1100 on the Cold Work Extrusion by Using Different Angles of Taper Die

2013 ◽  
Vol 594-595 ◽  
pp. 546-550 ◽  
Author(s):  
Mohd Jamir Mohd Ridzuan ◽  
Mohd Bin Sulaiman Hafis ◽  
K. Azduwin ◽  
A.R. Mohamed ◽  
S.N. Fitriah ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cold Work ◽  
Testing Machine ◽  
Extrusion Process ◽  
Pure Aluminium ◽  
Bio Oil ◽  
Different Types ◽  
Materials Used ◽  
Taper Die ◽  
Effect Of Surface

The study presented in this paper is focused on the effect of surfaces roughness of pure aluminium A1100 on the cold work extrusion process by three different angles of taper die. Different angles of taper die will affect the surface roughness of the workpiece. To protect the surface and to reduce friction, lubricants are often used in extrusion process [1]. Different lubricants may have different optimum taper die angle that are suitable to be applied. Two types of materials used in this experiment are steel SKD 11 for taper die and aluminium A1100 for workpiece and different angles applied are 30o, 45o, and 60o. Moreover, with respect to each angle, three different types of lubricants were used which are Daphne Draw S Series, Palm Olein, and EFB bio oil. The Universal Testing Machine and Surface Roughness Tester were used in this experiment. The result obtained from the experiment shows that at 30o of taper die angle were producing the smooth product surfaces for each lubricant and Daphne Draw S Series could reduce the surface roughness compared to other lubricant test.

Effects of Surface Roughness on Tribological Characteristics in Micro Double Cup Extrusion of Aluminum

2009 ◽  
Vol 419-420 ◽  
pp. 5-8
Author(s):  
Chao Cheng Chang ◽  
Chien Kuo Huang
Keyword(s):  
Surface Roughness ◽  
Early Stage ◽  
Surface Condition ◽  
Extrusion Process ◽  
Contact Interface ◽  
Workpiece Surface ◽  
Friction Factors ◽  
Constant Friction ◽  
Constant Shear Stress ◽  
The One

This study used the micro double cup extrusion of aluminum to investigate the effects of the surface roughness of workpiece and die on the tribological conditions involving mixed lubrication and plastic deformation. The aluminum billets with the diameter of 3 mm and the height of 4.5 mm in different surface roughnesses were prepared by grinding processes and used in the experiments under conditions of dry and molybdenum disulfide lubrication. To estimate the friction factors, the heights of the extruded cups were measured and compared with those predicted by finite element simulations using the law of constant shear stress. The results show that smaller workpiece surface roughness resulted in low and nearly constant friction in the early stage of the micro extrusion under the dry and lubricated conditions, which were reflected in the estimated friction factors. In the later stage of the extrusion processes, the workpiece surface finish became close to the one of the die for all tested conditions. The friction was clearly reduced in the dry condition but it became greater in the cases with the lubricated condition. The surface condition in the later stage of the micro extrusion process was believed to allow the lubricant to escape from the contact interface.

Evaluation of Paraffinic Mineral Oil as Lubricant in Cold Work Extrusion Process

2014 ◽  
Vol 554 ◽  
pp. 327-331 ◽  
Author(s):  
Samion Syahrullail ◽  
Mohd Ahyan Nurul Aini
Keyword(s):  
Plane Strain ◽  
Pure Aluminum ◽  
Cold Work ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Experimental Result ◽  
Friction Effect ◽  
Billet Material ◽  
Deformation Area ◽  
Taper Die

In this paper, the effect of frictional constraint from the application of three different viscosity of additive free paraffinic mineral oil as lubricant were investigated by cold work forward plane strain extrusion experiments. The experiment used a cold work plane strain extrusion apparatus consist of a pair of taper die and a symmetrical workpiece (billet). The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the higher viscosity, will lead to lower friction effect to the deformed area, as well as product area.

Abrasive Waterjet Cutting of Aluminum Alloys: Workpiece Surface Roughness

2013 ◽  
Vol 404 ◽  
pp. 3-9 ◽  
Author(s):  
Nihat Tosun ◽  
Ihsan Dagtekin ◽  
Latif Ozler ◽  
Ahmet Deniz
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Aluminum Alloys ◽  
Abrasive Waterjet ◽  
Traditional Methods ◽  
Workpiece Surface ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Area Of Application ◽  
Better Than

Abrasive waterjet machining is one of the non-traditional methods of the recent years which found itself a wide area of application in the industry for machining of different materials. In this paper, the surface roughness of 6061-T6 and 7075-T6 aluminum alloys are being cut with abrasive waterjet is examined experimentally. The experiments were conducted with different waterjet pressures and traverse speeds. It has been found that the surface roughness obtained by cutting material with high mechanical properties is better than that of obtained by cutting material with inferior mechanical properties.

On the Flexible Abrasive Tool for Nanofinishing of Complex Surfaces

2019 ◽  
Vol 18 (01) ◽  
pp. 157-166 ◽  
Author(s):  
Mithun Sarkar ◽  
V. K. Jain ◽  
Ajay Sidpara
Keyword(s):  
Surface Roughness ◽  
Corrosion Inhibitor ◽  
Abrasive Tool ◽  
End Mill ◽  
Complex Surfaces ◽  
Ball End Mill ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Processing Step ◽  
Finishing Tool

Nanofinishing of complex surfaces is an important but costly processing step for many products for performing their functions satisfactorily. This paper deals with the development of a flexible abrasive tool for nanofinishing of complex surfaces. A flexible finishing tool similar to the ball end mill is developed by curing Polydimethylsiloxane (PDMS). A bowl-shaped copper workpiece is finished to nanometer surface roughness value. Different sizes of abrasive particles are used to reduce surface roughness value of the workpiece. A corrosion inhibitor is mixed with the abrasive slurry to protect the finished copper workpiece surface. A final surface roughness value of 50[Formula: see text]nm has been achieved with a variation up to 70[Formula: see text]nm on different locations of the bowl-shaped workpiece.

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