Journal of Material Sciences & Engineering

Experimental Analysis for Lubricant and Punch Selection in Shear Extrusion of Aa-6063

Abstract

Ojo SO, Erinosho M and Ajiboye JS

Shear extrusion is a forming process which is based on combined backward cup-forward rod extrusion. This extrusion process is attractive due its potential to achieve severe plastic deformation thus enabling texture and microstructural control of materials. Furthermore, the economic potential of shear extrusion for mass production and production of complex shapes provides for numerous applications in automotive, transportation, aero-space and other industries. However, a trending challenge in the use of this method for complex shapes is the design and selection of tools to achieve a high quality product. This paper focuses on deep study of shear extrusion of AA-6063. The process was studied experimentally using variables which affect the forming load as well as the quality of the product. It is concluded from the load-displacement and stress plots that a punch with large diameter and small punch land is desirable for easy forming of the material during shear extrusion. Analysis of the effect of lubricants on deformation load and stress shows that palm oil lubricant remains the best lubricant of the four lubricants examined since its gives the minimum load obtained during shear extrusion.