TY - JOUR

T1 - Numerical simulation of friction extrusion

T2 - process characteristics and material deformation due to friction

AU - Diyoke, George

AU - Rath, Lars

AU - Chafle, Rupesh

AU - Ben Khalifa, Noomane

AU - Klusemann, Benjamin

N1 - Funding Information: Open Access funding enabled and organized by Projekt DEAL. This project has received funding from the European Research Council (ERC) under the European Union\u2019s Horizon 2020 research and innovation program (grant agreement No 101001567). Publisher Copyright: © The Author(s) 2024.

PY - 2024/5

Y1 - 2024/5

N2 - This study employs a finite element thermo-mechanical model, using a Lagrangian incremental setting to investigate friction extrusion (FE) under varying process conditions. The incorporation of rotation in FE generates substantial frictional heat, leading to significantly reduced process forces in comparison to conventional extrusion (CE). The model reveals the interplay between temperature, strain, and strain rate across different microstructural zones of the resulting wire. Specifically, the sticking friction condition in FE enhances initial shear deformation, aligning with a homogeneous spatial strain distribution and predicting complete grain refinement in the extruded wire, as per Zener-Hollomon calculations. On the other hand, under the sliding friction condition in FE, the shear deformation is reduced which results in an inhomogeneous microstructure in the extruded wire. The analysis of material flow in the workpiece reveals distinct transitions from the base material to the thermo-mechanically affected zones. The simulated process force, thermal history, and microstructure during sliding friction conditions align well with the findings from performed friction extrusion experiments.

AB - This study employs a finite element thermo-mechanical model, using a Lagrangian incremental setting to investigate friction extrusion (FE) under varying process conditions. The incorporation of rotation in FE generates substantial frictional heat, leading to significantly reduced process forces in comparison to conventional extrusion (CE). The model reveals the interplay between temperature, strain, and strain rate across different microstructural zones of the resulting wire. Specifically, the sticking friction condition in FE enhances initial shear deformation, aligning with a homogeneous spatial strain distribution and predicting complete grain refinement in the extruded wire, as per Zener-Hollomon calculations. On the other hand, under the sliding friction condition in FE, the shear deformation is reduced which results in an inhomogeneous microstructure in the extruded wire. The analysis of material flow in the workpiece reveals distinct transitions from the base material to the thermo-mechanically affected zones. The simulated process force, thermal history, and microstructure during sliding friction conditions align well with the findings from performed friction extrusion experiments.

KW - Dynamic recrystallization

KW - Friction condition

KW - Material flow behavior

KW - Microstructure zones

KW - Process simulation

KW - Thermo-mechanical condition

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=85189855053&partnerID=8YFLogxK

U2 - 10.1007/s12289-024-01825-z

DO - 10.1007/s12289-024-01825-z

M3 - Journal articles

AN - SCOPUS:85189855053

VL - 17

JO - International Journal of Material Forming

JF - International Journal of Material Forming

SN - 1960-6206

IS - 3

M1 - 26

ER -