Repetitive Upsetting Extrusion Process of Al 5452 Alloy: Finite Element Analysis and Experimental Investigation

In the last decade, the repetitive upsetting-extrusion (RUE) process has proved its potential in the bulk metal forming process in several investigations on severe plastic deformation (SPD) processes. The RUE process is currently being used to process bulk materials through grain refinement and consequently reaching better mechanical properties such as high strength and high toughness. Different process parameters affect the RUE process and the quality of the processed specimens. In the present investigation, the finite element analysis was carried out by using ABAQUS/CAE software to study the effect of die design on the RUE process, to find the minimum extrusion ratio for processing the Al 5452 alloy using the RUE process and determine the perfect height for the deformation zone in the RUE die. To that end, four cycles of successive RUE were performed on the Al 5452 alloy in the designed die. Microhardness distribution of the processed specimens was found to be more homogeneous and, by raising the RUE cycles, the average microhardness value in the processed specimens increased from 71.5 Hv (Non-cycle RUE processed specimen) to 145.1 Hv (specimen processed by 4 RUE cycles). It was also found that, by augmenting the RUE cycles, the compressive yield stress of the processed specimen increased from 136.622 MPa (Non-cycle RUE processed specimen) to 432.221 MPa (specimen processed by 4 RUE cycles).