Experimental and numerical analysis of extrusion process for AA 7178 alloy with varying process parameters

In the present study, both the experimental approach and the finite element analysis were employed to study the effects of the process parameters on the extrusion of aluminum-alloys AA 7178 rods. Aluminum alloy AA 7178 contains alloying elements like Zn, Mg & Cu etc. In cast condition, alloying elements are segregated along the grain boundaries and restrict for efficient flow for material. Moreover, the homogenized condition of alloying elements, is in the form of phase distributed in the matrix quite uniform manner, and facilitates flow of material. Nevertheless, the hard intermetallic phases present in Aluminum matrix restrict the flow of material and intern generates cracks. In the present study, the AA 7178 Al alloy is being cast, homogenized and then extruded in the form of rods of 15 mm diameter. Initially in order to optimize the process parameters for extrusion, Finite Element Analysis being carried out with the help of ANSYS LS DYNA Software. The FEM model provides the information such as load, rate of deformation, temperature for successful extrusion of AA 7178 Al alloy. Efforts are made to correlate the experimental values like load, final length and the diameter with FEA. So that the emphasis can be provided on the desirable properties of the material to get extrude. The process parameter such as temperature, rate of deformation, force etc are optimized to get defect free extrusion. (C) 2017 Elsevier Ltd. All rights reserved.