A Finite Element Thermal Model for Axisymmetric Cold and Hot

Extrusion using Upper Bound Technique

Dr S Kumar, Non-member
S K Prasad, Non-member
In this paper, a combined rigid plastic finite element (RPFE) model for steady state axisymmetric extrusion process is
proposed using a kinematically admissible velocity field obtained from the upper bound model earlier proposed by Kumar,
et al. Optimal power and temperature distribution in cold as well as hot extrusion processes are determined with RPFE
method using the deformation field obtained from upper bound method. Effects of various process parameters, such, as,
ram velocity, reduction, friction between die billet interface, die length and temperatures (initial billet, die and container
and surrounding) has been analysed using the proposed combined UB-RPFE method. The result obtained agrees well
with the experiment and analysis. The proposed model can further be extended for generalized solid shaped extrusion for
both hot and cold cases.
Keywords: Extrusion, Upper bound method; Finite element thermal formulation; Penalty method

INTRODUCTION deformation takes place at the exit cross-sectional plane of the

Several attempts have been made to analyse the cold as well as
hot extrusion problems. Some of them for cold cases are due to
Mehta, et al 1, Nagpal 2, Yang and Lee 3, Yang, et al 4-7, Gatto
and Giarda 8, Kiuchi, et al 9, Gunasekera and Hoshino 10,
Boer and Webster 11, Kudo 12, Lee, et al 13, Balaji, et al 14, Shim,
et al 15, Joun and Hwang 16, 17 and most recently by Kumar,
et al 18, 19. These works have reported different solution
approaches using upper bound, slip-line field and finite element
methods. Gunasekera and Hoshino10 proposed an upper bound
solution for streamlined dies and concluded that streamlined dies
are superior to straight converging dies for reducing extrusion
pressure in cold condition. However, none of these solutions are
of a general nature applicable to all non re-entry shapes except
Kumar, et al 18, 19 that uses a feature-based upper-bound model
with strain hardening suitable for die analysis of non re-entry cold
extrudable shapes.
In case of hot extrusion, some of the notable attempts made are
by Johnson and Kudo 20, Sheppard and Raybould 21, Altan and
Kobayashi 22, Altan, et al 23, Sheu and Lee 24, Tay, et al25,
Zienkiewicz, et al 26, Smelsor 27 and Reddy, et al 28. Faren and
Taylor 29 measured the plastic work and temperature rise in
tensile test and found that for steel, copper and aluminium, the
heat rise represents, respectively 86.5%, 90.2% to 92% and 95%
of plastic work, respectively. Singer and Coakham 30 made an
attempt to predict the emergent temperature of the extruded
product by taking a simple model in which complete
Dr S Kumar and S K Prasad are with the Department of Mechanical
Engineering, Institute of Technology, Banaras Hindu University,
Varanasi 221 005.
This paper (revised) was received on September 16, 2003. Written
discussion on the paper will be entertained till September 30, 2004.
flat die assuming heat flows only in axial direction. Reddy,
et al 28 analysed eight die profiles and found third order and
cosine die profiles to be the best, whereas, conical dies requiring,
maximum extrusion power. Reddy, et al 31 proposed a finite
element thermal model to determine the temperature distribution
in an axisymmetric hot extrusion process based on the
deformation field obtained by upper bound model.
In the present work, a feature based upper bound model
proposed by Kumar, et al 18, 19 has been used to propose a
combined upper bound-rigid plastic finite element (UB-RPFE)
model for axisymmetric cold and hot extrusion. Results obtained
from the combined model have been validated for cold and hot
extrusion and are found close to the experimental and analytical
results reported earlier by Singer and Coakham 30 and Reddy,
et al 31. Parametric study is also carried out using a third order
stream-lined die profile to study the effect of various parameters
like extrusion ratio, friction factor, ram velocity, die length and
temperatures (initial billet, container and surrounding) on
extrusion stress and temperature of the extrudate. It is found that
extrusion power varies with the die length, ram velocity, extrusion
ratio, friction factor, temperature etc. Optimal die length, which
minimises the extrusion power, is also determined using golden
section search method.
UPPER BOUND FORMULATION
Constitutive Equation
The strain rate tensor Î& ij is given as
1 æ ¶vi ¶v j ö÷
Î& ij = çç +
2 è ¶x j ¶x i ÷ø (1)
where vi and vj represent the velocity components along xi and

Vol 85, July 2004 59

xj directions, respectively. The constitutive law for rigid plastic/
viscoplastic material relating the deviatoric stress tensor s ¢ij and
the strain rate tensor Î& ij is expressed as
s ij¢ = 2m Î& ij
where m is the Levy-Mises coefficient. The generalized yield stress
s and generalized strain rate Î are defined as
3
s= s¢ s¢
2 ij ij
and
& 2
Î= Î& Î& (2)
3 ij ij
generalized strain Î is therefore, defined as Figure 1 Geometry of extrusion die and streamlines having generalised sec-
t tion
Î= ò Î& dt (3)
0

In general s depends on Î , Î& and temperature T.

(
s = F Î , Î& ,T ) (4)
In case of cold extrusion the effect of temperature can be
neglected on generalised stress s . These equations are used in
the proposed upper bound solution.

General Methodology

The upper bound theorem 32 can be expressed as

jT = ò Ws ij¢ * Î& ij* dW+ ò Si t Dvt *
Si dSi (5)
where W is the plastic deformation zone, t is the shear stress on
velocity discontinuity surfaces. Figure 2 The domain and boundary conditions (thermal) for axisymmetric
extrusion
The first term expresses the internal power of deformation over
the volume of the deformation zone, while the second term
Figure 2 the billet with an initial radius (Ro ) at entry, is extruded
represents the power dissipated in shearing the material over the
through a shaped (converging) dies constructed by a number of
velocity discontinuity surfaces and at the tool-work interface (ie,
pre-defined streamlines representing the surface of die, to the final
frictional power). Here, asterisk (*) indicates that the values of
generalised given section at the exit.
stress, strain rate and velocity discontinuity are obtained from an
assumed kinematically admissible velocity field. In order to construct the kinematically admissible velocity field
shown in Figure 2, the assumptions made are :
Proposed Kinematically Admissible Velocity and Strain Rate
Fields (i) Material of billet passing through the sector OMN at the
entry goes through the triangle O´M´N´ at the exit
The geometry of die and the velocity field in terms of streamlines
preserving the extrusion ratio.
in the steady flow process of extrusion are shown in Figure 1.
Velocity boundary conditions and the feature recognition (ii) Stream surface ONN´O´ consists of a number of
methodology proposed by Kumar, et al 19 for general class of streamlines (curved or straight) which start from a point
extrudable components for slicing the deformation zone, has (say P) at entry and end at a corresponding point (P´) at
been used in the present model. exit, maintaining the proportionality of the position.

One power element OMM´O´N´NO is chosen to demonstrate (iii) The material is incompressible, rigid, and perfectly plastic
the analytical construction of velocity and strain rate fields. In which follows a particular strain-hardening curve.

60 IE(I) Journal-MC
 (iv) The deformation zone is bounded by straight plastic entry and exit, the boundary conditions can be written as
boundaries at entry and exit sections of the die. ¶x ü
x = n sin f ; = 0ï
¶z
(v) The neutral line is the line joining CG of billet (ie, point ¶y ý at billet side( z = 0)
O) and CG of the extruded product cross-section (ie, point y = n cos f ; = 0ï
¶z þ
O’). (8)
na sin y ¶x ü
x= 2 ; =0ï
(vi) The elastic strain is small and can be neglected. Ro ¶z ï
na2 cos y ¶y ý at product side ( z = L)
(vii) Friction factor between the die and work piece material y= ; = 0ï
Ro ¶z ïþ
is assumed to be independent of slip.
where Ro is the billet radius; n is the distance from the axis
(viii)Deformation takes under place homogeneous and steady formed by joining the CG of the product and the billet shape
state conditions. (ie, O – O' ) to an arbitrary point C at the die entry f and y are
the angles between the plane of symmetry and the stream surface
Assumptions (i) and (ii) state that the reduction ratio is kept at entry and exit of the die, respectively and L is the die length.
constant with the subdivision of the material into small elements. Substituting these boundary conditions from equation (8) into
equation (7) gives
ie, for one power element OMM´O´N´NO
æ a sin y ö
æ Area of D O' M'N' ö x = n sin f + n ç 2 - sin f÷ f ( z )
ç ÷ è Ro ø
è cross-section area on product side ø
æ a cos y ö
y = n cos f + n ç 2 - cos f÷ f ( z ) (9)
æ Area of D OMN ö è Ro ø
=ç ÷ (6) z=z
è cross-section area on billet side ø
é z 2 z ù
3
where f = f ( z ) = ê 3 æç ö÷ - 2æç ö÷ ú (10)
If the coordinates of points M' and N' are (x1, y 1) and êë è L ø è L ø úû
(x2, y2), respectively and Aa is the cross-sectional area of the here f(z) =0 at z=0 and f(z)=1 at z=L (11)
extruded product shape. Equation (9) not only describes the coordinates inside the
plastically deforming region but the relationship between the
Then, O ¢M ¢ = a1 = (x 2
1 )
+ y12 ; and, O ¢N ¢ = a2 = (x 2
2 + y 22 ) Cartesian and n, f, z coordinate systems also. Although the
present analysis employs a third order curve represented by
b equation (10) for the description of die profile and the
cos y = assumed streamlines of particles, it is to be noted that
a1a2
function f(z) in equation (9) can be any general function of z
where b = ( x1x 2 + y1 y 2 ) . provided the function satisfies the given boundary conditions as
given in equation (11).
f Aa
From equation (6), sin y = . The Jacobian of equation (9) can be found as
p a1a2
x = nA + nBf
The streamlines on the stream surface can be represented by a y = nC + nDf
third order polynomial to satisfy the smooth entry and exit of the
z=z
material flow. Any coordinate along the streamline PP´ is where
formulated in a Cartesian coordinate system as a2con1f A
A = sin f; B = - A; con1 = a
Ro pa1a2
x = f1( z ) = b1z 3 + b2 z 2 + b3 z + b4 ü
ï a2con2
y = f 2 ( z ) = c1z 3 + c 2 z 2 + c 3 z + c 4 ý C = cos f; D = - C ; con2 = cos y
(7)
z=z ï Ro
þ
Hence
where bi and ci (for i = 1, 2, 3, 4) are constants, determined by é A + Bf C + Df 0ù
the boundary conditions. Since, the streamline does not produce J = ê nA'+nB' f nC '+nD' f 0ú
ê ú
any abrupt change in flow direction along the extrusion axis at êë nBf ' nDf ' 1úû

Vol 85, July 2004 61

Determinant of the Jacobian is, therefore, written as required for the calculation of total power (jT) are calculated as
det J = ng(f, z)
ji = ò Ws'ij Î& ij dV = ò Ws Î& dV
where
g ( f, z ) = [( A + Bf )(C '+ D' f ) - ( A'+ B' f )(C + Df ) ] . L f Ro
= ò ò ò s Î& det J dn df dz (14)
Assuming that the plastic zone is bounded by entry and exit shear
00 0
surfaces, the velocity field components can be obtained. Because
fR
of volume constancy, the velocity component along z-direction so
in the Cartesian coordinate system (vz ) should be vo at the
je = ò ò
3
[vr ] z =0 n dn d f (15)
00
entrance, and vp at the exit of die. vo and vp are the speeds of the
fR
billet and the outgoing product, respectively. vp can be described so
in terms of vo as
jo = ò ò
3
[vr ] z =L ndn df,
00

fRo2 1
vp =
a1a2 sin f
vo (12) where vr = [vx2 + vy
2 2
] (16)

The velocity components in x, y and z directions are given as Lf

ms o 1 ¶ ( x, z)
j f = òò vt df dz
nBf ' nDf ' 1 00 3 cos a ¶ ( f, z )
vx = v ; vy = v ; vz = v
g( f, z ) o g ( f, z ) o g ( f, z ) o 1

[
where vt = v x2 + v 2y + v z2 ] 2 , when n = Ro (17)
Strain rate components Î& ij can be found out using equation (1) and a is the angle between projected die surface and X-Z plane.
with the help of partial derivative. so
j int = Dvi Ai (18)
¶vi 3
¶v ¶u 3
=å i k Here Ai is the area of the ith interface formed by the coordinate
¶x j k =1 ¶uk ¶x j
points (0, 0, L), (xi, yi, L), (Ro sinf, Ro cos f, 0) and (0, 0, 0). The
Using the velocity fields given by these equations, it has been velocity discontinuity (Dvi) developed at the ith interface due to
found that the velocity boundary conditions are satisfied. relative velocity of ith and (i–1)th elements is evaluated as
Analytically it can be found that the incompressibility condition, Dvi =(vft –vft–1), where vft and vft–1 are average tangential velocity
( )
ie, Î& = Î& xx + Î& yy + Î& zz is approximately zero is also satisfied. of ith and (i–1)th elements. For ith element, vft is evaluated as

Hence, the proposed velocity field model fulfils the stringent vft =
[v + (v ) ] . Therefore, for n power elements, the total
o f i

requirement for the construction of a kinematically admissible 2

condition. interface power is (jint-tot) is
so n
Estimation of Extrusion Power and Average Ram Pressure j int-tot =å
Dvi Ai (19)
i =1 3
The total power consumed inside the die is the sum of total power Total power required in the extrusion process is sum of total
consumed within different power elements. One such element power consumed in various power elements of the shape. The
OMM´O´N´NO (Figure 2) is taken to evaluate total power (jT) average ram pressure (Pavg) and the relative forming stress (Rs )
consumed within the element. The total power consumed is given can be given as
as
jT Pavg
jT = ji + je + jo + j f + jint Pavg = and Rs = (20)
(13) pRo vo
2
so
where ji , je , jo , jf and jint are power losses due to plastic
FINITE ELEMENT FORMULATION
deformation, velocity discontinuities at entry and exit of the die,
friction along die-billet interface and shear velocity discontinuities Governing Equation
at the interface elements, respectively. If Î and s are general-
The differential equation of heat transfer for an axisymmetric
ised strain and generalised yield stress for the given strain
case, in cylindrical coordinates, is given by
hardening material without consideration of the redundant work
factor, and if so is the yield stress of the given material without é ¶ æ ¶T ö 1 ¶ æ ¶T ö ù ¶T
kê ç ÷ + çr ÷ ú + q& = rc (21)
considering strain hardening effects, then, various powers ë ¶z è ¶ z ø r ¶ r è ¶ r ø û ¶t

62 IE(I) Journal-MC
The present analysis deals with steady state case, hence right hand are T1, T2, T3, ……,TN . The steady state axisymmetric heat
side convective term vanishes and the governing equation (33) conduction problem can now be stated in an equivalent
is taken as variational form as

é ¶ æ ¶T ö 1 ¶ æ ¶T ö ù
kê ç ÷ + çr ÷ ú + q& = 0 (22)
[
dc = ò kÑ 2T + q& dTdV = 0 ] (25)
ë ¶z è ¶z ø r ¶r è ¶r ø û V

where q& is the heat generation rate per unit volume; vr and vz, ¶ æ ¶T ö 1 ¶ æ ¶T ö
where Ñ 2T = ç ÷ + ç r ÷
radial and axial velocity components; T, temperature; r, mass ¶z è ¶z ø r ¶r è ¶r ø
density; c, specific heat; and k, the thermal conductivity of the or, dc = dck + dc g + dcb
material.
Hence, c = ck + c g + cb (26)
Heat Generation
[ ]
Ne Ne Ns

One of the major difficulties faced in the thermal analysis of an c = å c e = å c ek + ceg + å c bs (27)
e =1 e =1 s =1
extrusion process is the estimation of the heat flux, flowing into where
1
the container and the die at the interface. This is needed in the dc ek = d ò k ( ÑT ) 2 dV
prescription of boundary condition at the interface. So far, V 2
proposing a partition function, which decides the fraction of heat 1
shared by the workpiece and tooling have tackled this problem.
Þ cek = ò k ( ÑT ) 2 dV (28)
V 2
Some research workers have also assumed the die to be insulated,
which is certainly not realistic. Further, it is difficult to determine & dV
dc eg = -d ò qT
V
the partition function accurately. To circumvent this difficulty,
the domain (WT)used for the thermal analysis includes a portion Þ ceg & dV
= - ò qT (29)
V
of the container as well as the die (Figure 2).
é ¶T ù
dcbs = - ò k ê dTdS
Since, some amount of heat generated in the deformation zone ¶n úû
S ë
may flow into the undeformed parts, the domain includes the
and Ns is number of convective boundaries.
undeformed parts of the workpiece at the inlet and exit regions.
æ1 ö
The entry and exit boundaries, namely, AB and EF, are chosen ie, dc bs = d òh ç T 2 - T¥T ÷ dS
sufficiently away from the deformation zone so as to take S
è 2 ø
advantage of the uniform conditions prevailing there. æ1 ö
Þ c bs = òh ç T 2 - T¥T ÷ dS (30)
è2 ø
The container and the die do not undergo any plastic S

deformation. Therefore, the contribution of plastic work to heat where T¥ is the ambient temperature.
generation term q& of equation (22) comes only from the
workpiece, ie, from the region ABCDEFA of the domain Finite Element Formulation for Conduction
(Figure 2). The other contribution to q& comes from the friction
From equation (28),
dissipation. Since, the interface BC between the workpiece and
1 éæ ¶T ö æ ¶T ö ù
2 2
the container is assumed to be frictionless, this contribution comes
cek = ò ò k ê ç + ú 2prdrdz
only from the interface CD, the die-work interface. Various 2 ê è ¶z ÷ø çè ¶r ÷ø úû
ë
components of heat generation in the proposed thermal model
is given as: é K 11 K 12 K 13 K 14 ù ìT1 ü
q& = 0 in the region BGHDCB êK K 24 ú ïï T2 ïï
¶c ek K 22 K 23
=ê úí ý
21
q& = b s Î& in the region ABCDEFA (23) ¶{T } ê K 31 K 32 K 33 K 34 ú ï T3 ï
ê ú
q& = tvt along the interface CD (24) K
ë 41 K 42 K 43 K 44 û ïîT4 ïþ

VARIATIONAL INTEGRAL FORMULATION

¶c ek
= [ K ] {T }
e e
Hence (31)
Considering the domain subdivided into Ne number of elements, ¶{T }
consisting of N nodal points, the temperatures of nodal points where Kij are the elements of conduction matrix.

Vol 85, July 2004 63

Finite Element Formulation for Heat Generation nodal values of temperature converge within 0.1% between two
successive iterations. The computer program is encoded in
From equation (29), Fortran77 language. It has been found that 0.30s of
c eg = - ò ò qT
& 2prdrdz computational time is required for each iteration on Pentium IV
(1.7 GHz) machine.
ìG1 ü
¶c eg ïG ï
ï 2ï If the die profile is to be minimised on the basis of power
= - í ý = - {G} ,
e
Hence (32)
¶{T } G
ï 3ï
minimisation criteria, then the die-length has to be changed
ïîG4 ïþ according to the Golden Section Search Technique. Then the
deformation field also needs to be changed, and for each
where Gi are the elements of generation matrix.
deformation field the iterative process should be continued to get
Finite Element Formulation for Convective Boundary the temperature distribution. After convergence of the nodal
temperature, again the die length changes according to Golden
From equation (30), Section Search Technique, until optimum die length is achieved.
æ1 ö
cbs = ò h ç T 2 - T¥T ÷ dS RESULTS AND DISCUSSIONS
S
è2 ø
¶c eb é H11 H12 ù ìT1 ü ì h 1 ü Various deformation characteristics are obtained for cold as well
í ý - í ý = [ H ] s {T } s - {h}
e e
=ê ú
e
¶{Ts } ë H 21 H 22 û îT2 þ îh 2 þ as hot extrusion using the proposed UB-RPFE thermal model.
(33) The results for hot extrusion case are obtained for Al 6061
where Hij and hi are the elements of LHS and RHS convective aluminium as the billet material. The thermal properties of
matrices, respectively . Al 6061 as given by Sheu and Lee24 are
Hence, for an element combining all three equations (31),
Density (r) = 2700 kg-m-3
(32) and (33) gives:
Thermal conductivity(k) = 665 T -0.17 Wm-1K-1
[ K ] e {T } e + [ H ] es {T } es = {G } e + {h} e (34)
The global matrix can be written as: Specific heat (C ) = 285 T 0.205 Jkg-1K-1

¶c g The flow stress of aluminium 6061 has been determined from

= [ K ] {T } + [ H ] s {T } s = {G} + {h} = 0
g g g g g g
¶{Ts } an upsetting experiments at four temperatures (350°C, 400°C,

{[ K ] }
450°C and 500 °C) as provided by Sheu and Lee 24 and Reddy,
+ [ H ] s {T } = {G} + {h}
g g g g g
Þ et al 31 are considered here
s = F (T ) Î& n (T ) MPa
or, [ K T ] g {T } g = {FT }
-1 where
{T } = [KT ] {FT }
g g
so, (35) F (T )= –5207.310 672 328+(24.135 892 180 55)T
–(0.036 277 709 0824)T 2
Solution Procedure +(1.787 999 465 51×10-5)T 3

For solving these finite element thermal model, strain rate is taken and
average over the element. Also temperature, flow stress and n(T )= –27.175 164 962 21+(0.117 078 933 291)T
velocity are assumed constant over an element and are taken –(1.675 199 630 559×10-4)T 2
average. Equation (35) is solved iteratively by ‘penalty’ approach +(7.999 998 306 888×10-8)T 3.
using the deformation field obtained from the upper bound where T is the average temperature of the plastic zone in Kelvin.
method. The deformation field depends upon the extrusion ratio, These material properties are strictly valid within the temperature
die length and ram velocity. Flow stress of the material is a range from 400°C to 500 °C.
function of strain, strain-rate and temperature. Since, extrusion
ratio, die length and ram velocity do not change from iteration In the thermal model steel is used as the tooling material for
to iteration, the deformation field obtained from upper bound which the material properties are:
method, remains same in each iteration. But temperature field Density (r) = 7860 kg-m-3
changes in each iteration. Therefore, only flow stress s needs Thermal conductivity (k) = 54.76 Wm-1K-1
to be updated for each iteration using the temperature field of Specific heat (C ) = 501.6 Jkg-1K-1
the previous iteration. Iterative process is continued until the Heat transfer coefficient for air(h) = 80 Wm-2K-1

64 IE(I) Journal-MC

Figure 3 Finite element model for thermal analysis using third order die
profile (number of nodes = 142, number of elements = 115)
Figure 4 Variation of strain rate with fractional die length along streamlines
starting at various radial locations for third order die (Ro=19.4 mm, L/Ro=1.0,
vo=10 mm/s, %r =40)
Figure 5 Comparison of extrudate temperature with experimental value at
different ram speeds (Ro= 18.875 mm, Tb = Td = T¥ =32 °C, extrusion ratio
= 16, yield stress of super pure Al at no strain hardening = 25.0 MPa
Vol 85, July 2004
Figure 4 shows variation of strain rate within the deformation
zone along different streamlines, starting at different radial
positions from the centre of gravity. It is observed that strain rate
is maximum along the die-billet interface in case of third order
polynomial die.
Singer and Coakham30 conducted an experiment for predicting
temperature change during an axisymmetric cold extrusion.
Super pure aluminium bar with flow stress without strain
hardening as 25 MPa, was extruded through a square die at
different ram speeds and temperature at the exit section of
die was measure for each speed. The results obtained by the
present UB-RPFE thermal model taking sticking friction
condition are compared with the experimental results of Singer
and Coakham 30 in Figure 5. It can be seen that the proposed
UB-RPFE thermal result compares well with the experiment.
However, at higher ram velocity the rise in temperature is found
to be higher. This is because the model is taken for the steady
state condition, which is not the actual one.
Figure 6 Effect of friction on extrusion stress for third order die with reduction
(vo = 7 mm/s, L/Ro = 1.0)
Figure 7 Temperature distribution in the thermal model for third order die
(Ro= 15 mm, %r = 30, m = 0.2, vo = 40 mm/s, L/Ro = 1, Tb = 410 °C,
Td = 350 °C, T¥ = 30 °C)
65
Figure 6 shows effect of friction on extrusion stress with different
reductions for a third order die profile. It is observed that
extrusion stress increases with increase in both friction and
reduction. There is no significant effect of ram velocity on the
extrusion stress. AISI 4041 steel is taken as the billet material for
which the material property is given as
s = 418.9 + 699.0 Î 0.266 MPa
Thermal analysis for hot extrusion is carried out using the
deformation field obtained by the upper bound model. The
results are based on the extrudate temperature depending on
the initial billet temperature. Effects of various parameters on the
rise in temperature of billet material are obtained using a third Figure 10 Comparison of temperature distribution along the die-work inter-
order die profile, since material properties are sensitive to face at two ram velocities (%r =30, m =0.2, T b =410 °C, L/R o=1.0,
temperature at which hot extrusion are generally carried out. Td =350 °C, T¥=30 °C)
Figure 7 shows temperature distribution (isotherms) within the
domain of thermal analysis. It is observed from figure that
the rise in temperature is more near the exit section of the die.
Figure 8 shows temperature distribution along the die-billet

Figure 11 Comparison of temperature distribution along the die-work inter-

face at two die lengths (%r = 30, Tb = 410 °C, vo= 40 mm/s, L/Ro=1.0,
Td = 350 °C, T =30 °C)
¥

interface at different reductions. It is observed that temperature

Figure 8 Comparison of temperature distribution along the die-work inter-
face at two reductions (m = 0.2, T b = 410 °C, vo= 40 mm/s, L/R o=1.0,
Td =350 °C, T =30 °C)
¥
rise is more at higher reduction. Also variation in temperature
increases as the billet reaches towards the exit section. Figure 9
shows temperature distribution along the die-billet interface at
two initial billet temperatures. It is observed that variation in
temperature of billet is less at higher initial billet temperature and
more at lower initial billet temperature. Figure 10 shows the effect
of ram speed on the rise in temperature along the die-billet
interface. It is observed that at higher ram velocity, temperature
rise in billet is much more than at lower velocity. However, there
may such a ram velocity for which the heat generated within the
deformation zone equals to heat loss from the thermal model. This
speed may be used for designing isothermal conditions in
extrusion.

Figure 11 shows the effect of die-length on the temperature

increase along the die-billet interface. It is found that increasing
die length increases temperature rise along the die-billet interface,
Figure 9 Comparison of temperature distribution along the die-work inter-
face at two initial billet temperatures (%r=30, m=0.2, vo=40 mm/s, L/Ro=1.0,
since the temperature rise depends on the heat generated within
Td =350 °C, T =30 °C) the deformation zone. Heat generation depends on the internal
¥

66 IE(I) Journal-MC
power of deformation and frictional power. Variations of different
parameters affect the power constituents thus affecting the heat
generation within the deformation zone. The various
characteristics described on rise in temperature of billet are due
to change in the heat generation.
CONCLUSIONS
The proposed combined UB-RPFE model can be used for
optimal die design in cold as well as hot extrusion based on power
minimisation criterion. The optimum die length increases with
increasing reduction of area however decreases with increasing
friction factor. It is found that the temperature rise in the billet
during extrusion is higher at the exit section of the die. The
temperature rise increases with increasing reduction of area,
friction factor, ram velocity and beyond optimal die length. The
trend of the results obtained for cold as well as hot extrusion
agrees well with the experimental results and the earlier work.
The proposed model can be easily extended for generalised
shapes of cold and hot extrusion.
ACKNOWLEDGEMENTS
The financial support of the Department of Science and
Technology (India) [Grant No. 100/IFD/488820001-02 Dated
19.0 2002] is gratefully acknowledged. Authors wish to express
their thanks to Prof G K Lal of IIT Kanpur and Prof N K Samria
of Mech Engg Dept IT, BHU, Varanasi, for their help and
support.
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