Effects of lubricants and billet geometry on the extrusion of AA6063/5% SiCp composites

Lubricants are necessary for metal forming to avoid direct contact, adhesion, transfer, and scratches from materials and tools. It is also essential for increasing tool durability and reducing energy use. The work aims to study the effects of lubricants and billet geometry on the extrusion of AA6063/5% SiCp. The lubricants were used such as graphite, zinc stearate, and molybdenum disulphide. The friction factor has been determined by the lubricant effect and billet geometry. The simulation was done for the lubricated condition which was compared with experimental results. It was found that improved billet quality was obtained by the graphite-lubricated 12:8 configuration die profile. Also, the friction factor for the graphite-lubricated 12:8 configuration dies profile was 10.5% less compared to other configure profiles. Scanning electron microscopy was used to investigate the surface of the lubricated extruded component, and samples were examined utilizing energy-dispersive X-ray analyses.

Automated summary

Lubricants are essential in metal forming to prevent direct contact, adhesion, transfer, and scratches, and also to increase tool durability and reduce energy consumption. This study investigates the effects of lubricants and billet geometry on the extrusion of AA6063/5% SiCp. Graphite, zinc stearate, and molybdenum disulphide were used as lubricants, and the friction factor was determined based on the lubricant effect and billet geometry. Simulation was performed under lubricated conditions and compared with experimental results. The use of graphite-lubricated 12:8 configuration die profile resulted in improved billet quality, with a 10.5% lower friction factor compared to other configurations. Scanning electron microscopy and energy-dispersive X-ray analyses were used to examine the surface of the lubricated extruded component.