Proceedings of the World Congress on Engineering 2015 Vol II

WCE 2015, July 1 - 3, 2015, London, U.K.

Effect of Punch Diameters on Shear Extrusion

of 6063 Aluminium Alloy
Mutiu F Erinosho1, Saheed O Ojo2, Joseph S Ajiboye3, Esther T Akinlabi4

have revealed that the process can also be used as a novel

AbstractThis paper reports the effect of punch diameters on the texture control and microstructure control method for long
shear extrusion of 6063 Aluminium alloy. During the shear extrusion coiled strips by introducing shear textures in addition to its
process, Aluminium billets of considerable diameter 30 mm and capacity of being highly productive [3]. The mechanics of
height 25 mm were inserted in a die hole and different punches of plastic deformation provide the means for determining how
diameter 12 mm, 14 mm, 16 mm and 18 mm respectively were the metal flows in different forming operations and to obtain
allowed to come in contact to perform the shear operation. The setup the desired geometry through plastic deformation; and also the
took place under a hydraulic press with maximum capacity of 600 means for determining the expected mechanical and physical
kN. This work is aimed at studying the selection of the optimum properties of the metal produced [4]. The principal magnitude
punch diameter for shear extrusion using local groundnut oil as the
of the maximum load is required to give 6063 Aluminium
lubricant. Different extrusion pressures were measured and the punch
alloy a maximum displacement during extrusion which made
with a diameter of 18 mm gives the highest load of 77.7 kN while the
it possible for paramount plastic deformation. The travel of a
punch with a diameter of 12 mm gives the lowest load of 51.2 kN.
An indication shows that, an increase in the punch diameters led to
punch during deformation by extrusion process also depends
an increase in the height of the extrudates and this in turn reduces the on the magnitude of the maximum pressure and the geometry
stress induced. of the die coupled with the intergral properties of the billet [5].
The extrusion load increases with the shape ratio of a billet;
Keywords 6063Aluminium alloy, die, extrudates, press, punch and the forward and backward extruded lengths can be
predicted from the diameter, height and flow stress of a billet
[6]. The pressure forces applied during extrusion process are
smaller in the case of combined extrusion than the forming
I. INTRODUCTION
extrusion products in two technological operations which are
063 ALUMINIUM alloy is a solid solution strengthened the cylindrical part of the product (forward-extruded) and the
6 material and its alloying elements may reduce the rate of
recovery by impeding dislocations glide and retarding their
sleeve part (backward-extruded) [7]. It is important to
streamline the flow of material from the inlet to the exit, and
movement to achieve a relatively homogeneous ultra-fine as a practical measure to fine tune the flow balance and
microstructure [1]. Basically, the shear extrusion theory was product dimensions, flow adjustment devices could be
derived from the combination of backward cup and forward included in the die design [8]. Extrusion is used for the
rod extrusion theory. The extrusion force in shear extrusion processing of Al alloy for shape forming, consolidation, and
method of severe plastic deformation for fabrication of metal rearrangement of reinforcements. It was reported that
shapes with ultra-fine structures is far lower than that of extrusion speed does not change the hardness of aged and
simple forward rod extrusion or backward cup extrusion. This non-aged samples in a greater way and the hardness values
severe plastic deformation has been used to improve a unique obtained for the samples increased with the aging effect due to
combination of high strength and ductility [2]. The process the precipitation hardening [9]. The heat treatment of 6063
involves a shearing deformation during the metal forming cold-drawn Aluminium tubes were characterized for yield
process. Further works on continuous deformation process strength, ultimate tensile strength, and fracture elongation
during aging. It was revealed that the result shows an increase
Mutiu F. Erinosho is a doctorate candidate in the Department of in the properties; and at maximum the properties decreased
Mechanical Engineering Science, University of Johannesburg, Auckland Park
Kingsway Campus, Johannesburg, South Africa, 2006. (Phone-
due to over-aging [10].
+27747425924; E-mail: mferinosho@uj.ac.za).
Saheed O Ojo is a doctorate fellow in the Department of Structural, This research work is aimed at unveiling the potentials in
Geotechnical and Building Engineering, Politecnico di Torino, 3.so Duca shear extrusion process in terms of reduction in the extrusion
degli Abruzzi 24, 10129 Torino, Italy. (E-mail: d031290@polito.it).
Joseph S Ajiboye is a Senior Lecturer in the Department of Mechanical pressure and the production cost, improved structure
Engineering Science, University of Lagos, Akoka, Nigeria. (E-mail: refinement of the product and high productivity.
joeajiboye@hotmail.com).
Esther T. Akinlabi is an Associate Professor in the Department of
Mechanical Engineering Science, University of Johannesburg, Auckland Park
Kingsway Campus, Johannesburg, South Africa, 2006. (E-mail:
etakinlabi@uj.ac.za).

ISBN: 978-988-14047-0-1 WCE 2015

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2015 Vol II
WCE 2015, July 1 - 3, 2015, London, U.K.

II. MATERIALS AND METHOD Therefore, in order to ensure that the punch is of proper
strength that can withstand deflection forces, a punch length
A. Equipment Design of 60 mm was selected for the design.
This relates to the considerations in the choice of equipment Fig. 1 shows the punches of different diameters (12 mm, 14
and tooling needed for the experiment to be conducted mm, 16 mm, and 18 mm) with a punch land of 3.0 mm.
successfully. It involves the design of the extrusion die, punch
design, selection of the press, and the design of the fixture and
other accessories. The material used for the extrusion is an
Aluminium-6063 alloys which was obtained at the Tower
Aluminium Industry, Sango Ota, Nigeria. Table I depicts the
chemical composition of the Aluminium-6063 alloys. Local
groundnut oil was used as the lubricant due to its availability
and low cost effective.

TABLE I
CHEMICAL COMPOSITION OF 6063 ALUMINIUM ALLOY
Alloying Composition Alloying Composition
Element (%) Element (%)
Si 0.518 Sn 0.007
Fe 0.251 Pb 0.000
Cu 0.007 Zn 0.100
Mn 0.006 Ti 0.013
Mg 0.521 Al 98.62

B. Die Design
The dies and tooling used in this research work was Fig. 1 Punches with different diameters
designed to withstand considerable amount of high stresses.
This assembly was designed for easy replacement of punches The extrusions were conducted with a vertical hydraulic press
of varying sizes. The die stack consists of the die body, die of 600 kN capacity. A constant extrusion speed was
shoe and the punch plate. The die was constructed as a flat maintained for all the punches. The vertical press was selected
faced die in order to allow metal upon entering the die to shear due to its advantages of easier alignment between the press
internally to form its own die angle. A parallel land on the exit ram and the tools.
side of the die helps to strengthen the die and allows for
reworking of the flat face on the entrance side of the die
without increasing the exit diameter. III. RESULT AND DISCUSSION
C. Punch Design
A. Extrudates
The maximum allowable punch length, Lm is calculated using
the formula
Figs. 2 a-d show the extrudates of the 6063 Aluminium
alloy billet after undergoing the extrusion process with the
punch diameters of 12 mm, 14 mm, 16 mm, and 18 mm
(1) respectively.
From Fig. 2, there is an indication that an increase in punch
diameters lead to an increase in the height of the extrudates.
Where D = diameter of punch, mm, fs = shear stress, MPa, t = The heights of the extrudates are 2.5 mm, 4.8 mm, 7.4 mm
material thickness, mm, E= modulus of elasticity of punch and 10.2 mm respectively. The depth initiated by the punches
material, N/mm2 and D/t= 1.1 or higher was also observed. The smaller the punch diameter, the deeper
the depth formed on the extrudate and this can be attributed to
Using the formula in equation (1) for a punch made of high the small surface area in contact with the specimen. The
carbon steel material, removal of the punch within the aluminium billet is assisted
fs= 758.3 MPa, E= 203.4 109 N/mm2, D = 12 mm, 14 mm, 16 with the lubricant used. The deformation spreads towards the
mm, and 18 mm respectively. rear end and the periphery of the billet and the flow becomes
The maximum punch length, Lm for the various punch more significant leading to an expansion of the deformation
diameters is obtained thus, Lm (12 mm) = 81 mm; Lm (14 mm) zone [11].
= 94 mm; Lm (16 mm) = 107 mm; and Lm (18 mm) =120 mm.
.

ISBN: 978-988-14047-0-1 WCE 2015

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2015 Vol II
WCE 2015, July 1 - 3, 2015, London, U.K.

The graph shows an increasing load with increasing ram

displacement. That is, the higher the load applied, the higher
the displacement of the ram. The load obtained for the punch
diameter of 18 mm was the highest as compared to other
punch diameters. Relating this phenomenon to the Fig. 2d
with the height of the extrudate formed, it can be deduced that
the force applied on the billet was high.

IV. CONCLUSION

(a) (b) Shear extrusion process has been one of the approaches for
plastic deformation. The mechanics of plastic deformation
determine the flow behavior of materials with the desired
geometry.
Based on the results obtained, an indication shows that the
largest diameter punch (18 mm) gives the lowest stress level
due to the large contact area spread on the surface of the billet.
This punch gives the lowest yield stress, thus causing the
material to deform easily and can be referred to as the
optimum since it was able to withstand a high load without
deflection while the small punch of 12 mm was considered not
appropriate for the operation since it deflected on high load.
(c) (d) REFERENCES
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ISBN: 978-988-14047-0-1 WCE 2015

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)