A Comprehensive Model for Predicting Profile Exit Temperature of Industrially Extruded 6063 Aluminum Alloy

The effects of extrusion parameters on the resulting profile exit temperature of industrially extruded 6063 aluminum alloy have been studied using statistical design of experiments (DOE). Two operating parameters (initial billet temperature and ram speed) and three geometrical parameters (extrusion ratio, profile average thickness, and number of die cavities) were investigated. A statistical model was obtained for predicting profile exit temperature with very close agreement between predicted and measured values. Present results indicated that the main contribution towards profile exit temperature comes from plastic work promoted by high extrusion ratios, high initial billet temperatures, and high ram speeds. Further contributions are promoted by parameters affecting friction and redundant work components. In addition to single-factor effects, profile exit temperature was revealed to be affected by a set of complex two-factor and three-factor interactions between the different operating and geometrical parameters. The most remarkable two-factor interactions were shown to exist between extrusion ratio and number of die cavities and between initial billet temperature and ram speed. Complex three-factor interactions have been shown to exist between extrusion ratio, initial billet temperature, and ram speed. These interaction effects are quantified in the present model and are further qualitatively discussed in terms of their effects on the resulting profile exit temperature.