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.

Alternative Lubricants: Study on Plant-Based Lubricants in Metal Forming Process

2016 ◽  
Vol 819 ◽  
pp. 469-473
Author(s):  
M.A. Nurul ◽  
Samion Syahrullail
Keyword(s):  
Pure Aluminum ◽  
Cold Work ◽  
Viscosity Index ◽  
Experimental Result ◽  
Forming Process ◽  
Lower Viscosity ◽  
Experimental Apparatus ◽  
Billet Material ◽  
Metal Forming Process ◽  
Taper Die

In this paper, the effect of metal-to-metal contact from the application of plant-based lubricants, RBD palm olein and jatropa were investigated by cold work forward plane strain extrusion experiments. A pair of taper die and a symmetrical workpiece (billet) was placed inside extrusion rig which acted as main experimental apparatus. The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the lower viscosity index, will lead to lower friction effect to the deformed area, as well as product area.

DETERMINING ALTERNATIVES FOR METAL FORMING LUBRICANTS: A STUDY USING PLANE STRAIN COLD EXTRUSION PROCESS OF JIS-A1100 PURE ALUMINUM BILLET

2015 ◽  
Vol 74 (10) ◽  
Author(s):  
M. A. Nurul ◽  
S. Syahrullail ◽  
M. N. Musa
Keyword(s):  
Product Quality ◽  
Plane Strain ◽  
Renewable Resources ◽  
Metal Forming ◽  
Pure Aluminum ◽  
Cold Work ◽  
Cold Extrusion ◽  
Film Material ◽  
Ability To Act ◽  
Taper Die

Lubrication is very important in metal forming processes to control wear and friction at the interface between interacting surfaces. Non-renewable resources, such as plain mineral oils are widely used due to its ability to act as a supplier to wearing contacts; it may function as a film material or even sustain chemical transformations to become a film material. Since non-renewable resources can only last for more than a decade, renewable resources have been studied in order to find alternative lubricants that can present similar results in terms of extrusion load and product quality. Two renewable lubricants were analyzed (RBD palm olein and jatropha) together with an additive free paraffinic mineral oil, VG32, which acted as a reference lubricant. The experiment used a cold work plane strain extrusion apparatus that consists of a pair of taper die and a symmetrical work piece (billet). The billet material was made of annealed pure aluminum JIS-A1100 with radius of 5 mm in the deformation area. It was found that higher viscosity lubricants produced low extrusion load and friction during metal forming process with no major severe wear on product quality. Based on the results, it was proven that renewable resource based lubricants can be considered as a substitute for common lubricants used in the industry, since they present similar results with those currently applied in the industry. 

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.

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.

Comparison of Slip-Line Solutions With Experiment

1956 ◽  
Vol 23 (2) ◽  
pp. 225-230
Author(s):  
E. G. Thomsen
Keyword(s):  
Plane Strain ◽  
Pure Aluminum ◽  
Maximum Shear Stress ◽  
Yield Condition ◽  
Approximate Solutions ◽  
Extrusion Process ◽  
Experimental Results ◽  
Wall Friction ◽  
Axially Symmetric ◽  
Area Reduction

Abstract Plane-strain and axially symmetric approximate solutions for a perfect plastic are compared with experimental results obtained from the extrusion of a billet of commercially pure aluminum. The extrusion process was carried out at room temperature under essentially negligible external wall friction with a reduction of area of 87.8 per cent. It is found that the plane-strain solution is in good agreement with the experimental results, if a constant k = σ̄/2 = 20,000 psi (maximum shear stress for Tresca’s criterion) is substituted in the plane-strain solution. The flow stress (σ̄ ≅ 40,000 psi) was determined from a property test for the aluminum billet, at a strain equivalent to the uniform deformation in the extrusion (i.e., same area reduction without shear deformation). It is found that the Haar and von Karman yield condition is not valid for the present case, and further that the axially symmetric solution demonstrates no real advantage over the simpler plane-strain solution in predicting the stress distribution in an axially symmetric extrusion problem.

The Effect of Lubricant Viscosity in Cold Work Forward Extrusion

2014 ◽  
Vol 554 ◽  
pp. 291-295
Author(s):  
Samion Syahrullail ◽  
Shunpei Kamitani ◽  
Kenji Nakanishi
Keyword(s):  
Sliding Friction ◽  
Pure Aluminum ◽  
Cold Work ◽  
Metal Flow ◽  
Extrusion Process ◽  
High Viscosity ◽  
Extrusion Force ◽  
Workpiece Surface ◽  
Forward Extrusion ◽  
Lubricant Viscosity

In cold work extrusion, lubricants play an important role in lubricating the tool and workpiece surfaces, preventing metal-to-metal contact and reducing sliding friction, so that the workpiece can be extruded smoothly without severe wear due to lubricant starvation. In this paper, the influence of lubricant viscosity in cold work forward extrusion was investigated. The lubricants were additive-free, paraffinic mineral oil, which may have low, medium or high viscosity. The workpiece material was pure aluminum A1100, extruded with extrusion ratio of 3. The analysis focused on extrusion force, workpiece surface roughness after the extrusion process and the metal flow in the deformation zone of the workpiece. Using the visioplasticity method, the sliding velocity was calculated from the metal flow. Results showed that, the higher the lubricant viscosity, the lower the extrusion force generated. However, a high-viscosity lubricant produces coarser workpiece surface conditions after the extrusion process.

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.

The Influence of Lubricant Viscosoty in Cold Work Forward Extrusion Using Micro–Pits Tool

2012 ◽  
Vol 58 (2) ◽  
Author(s):  
A. Norhayati ◽  
S. Maizan ◽  
H.M. Zin ◽  
J. Y. Wira ◽  
W. B. Wan Nik ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plane Strain ◽  
Cold Work ◽  
High Viscosity ◽  
Experimental Results ◽  
Grid Pattern ◽  
Mineral Oils ◽  
Low Viscosity ◽  
Billet Surface ◽  
Taper Die

The present research concerns on the study of the effects of micro–pits arrays formed on taper die using cold forward plane strain extrusion experiments. Each pit was of reverse pyramids configuration having 330 microns diagonal length. The pits were 860 microns apart each others. Two additive free paraffinic mineral oils with low viscosity (P2) and high viscosity (P3) were used in this experimental work. The experimental results were compared with the results obtained from the plane strain extrusion experimental works with taper die without micro–pits (NA). The experimental results focused on the extrusion load, billet surface roughness and billet grid pattern on inclination slope. From the results, the existence of the micro–pits array on the taper die surface affected the extrusion load. At the same time, the micro–pits array affected the extruded billet surface roughness after the experiments. From this experiment, we could conclude that the micro–pits formed on the taper die (PA) would control the frictional constraint on the taper die compared to those without the micro–pits (NA). However, high viscosity lubricant (P3) was found to cause more effects compared to low viscosity lubricant (P2).

Microstructure and Mechanical Properties of Twist Extruded Pure Aluminum Processed by Post-Rolling

2011 ◽  
Vol 264-265 ◽  
pp. 183-187 ◽  
Author(s):  
S. Ranjbar Bahadori ◽  
Seyed Ali Asghar Akbari Mousavi ◽  
A.R. Shahab
Keyword(s):  
Grain Size ◽  
Pure Aluminum ◽  
Rolling Process ◽  
Extrusion Process ◽  
Ultrafine Grained ◽  
Twist Extrusion ◽  
Aluminum Sample ◽  
Deformation Processes ◽  
Ultrafine Grained Materials ◽  
Extrusion Method

Interest in processing of bulk ultrafine-grained materials has grown significantly over the last years. Severe plastic deformation processes such as twist extrusion have been the essence of these researches and used to decrease the bulk grain size. The bulk gain size can reduce if twist extrusion process combines with a conventional forming technique. In this study, the effects of reduction by employing the rolling process after the twist extrusion method were considered. The twist extrusion process of the commercially pure aluminum sample was carried out using a twisted die with 60º die angle, and the samples were processed through rolling subsequently. As a result of rolling, average microstructure grain size decreased significantly and the hardness amount increased accordingly

Investigation on the Effect of Geometrical Shape of Cold Direct Extrusion on Commercially Pure Aluminum Alloyed by 4% Cu

2015 ◽  
Vol 1105 ◽  
pp. 182-189 ◽  
Author(s):  
Adnan I.O. Zaid ◽  
S.M.A. Al-Qawabah
Keyword(s):  
Mechanical Behavior ◽  
Pure Aluminum ◽  
Extrusion Process ◽  
Control Area ◽  
Geometrical Shape ◽  
Compression Tests ◽  
Maximum Enhancement ◽  
Cross Sectional ◽  
Direct Extrusion ◽  
Cu Alloy

Al-4% Cu alloys are now widely used in many engineering applications especially in robotic, aerospace and vibration control area. The main problem arises from the weakness of their mechanical characteristics. Therefore, this study is directed towards enhancing the mechanical properties through severe plastic deformation, hence it is anticipated that cold direct extrusion process may enhance their mechanical behavior. This was performed through using three different cross sectional dies namely; circular, square, and rectangular that have the same cross sectional area. The general microstructure, microhardness, and compression tests were performed on each specimen produced before and after extrusion for Al and Al-4% Cu alloy. It was found that the maximum enhancement in mechanical behavior was achieved after extrusion through the rectangular shape for both Al and Al-4% Cu alloy at 0.2 strain by 143% for Al and 134.8% for Al-4%Cu wt.; similarly the hardness of both of them was improved where a maximum of 141.8 % was obtained for Al-4% Cu wt. in case of rectangular cross sectional die.

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