Process mechanics in Friction Stir Extrusion of magnesium alloys chips through experiments and numerical simulation. (October 2017)

• Record Type: Journal Article
• Authors: Baffari, Dario; Buffa, Gianluca; Campanella, Davide; Fratini, Livan; Reynolds, Anthony P.
• Is Part Of: Journal of manufacturing processes. Volume 29(2017)
• Page Start: 41
• Page End: 49
• Publication Date: 2017-10
• Subjects: Friction Stir Extrusion -- Recycling -- FEM -- Magnesium alloys; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2017.07.010
• Languages: English
• ISSNs: 1526-6125

Abstract

Graphical abstract: Highlights: A helical material flow was identified in the extrusion channel through a copper marker. Tool force has predominant effects with respect to tool rotation on process temperature. Friction losses on extrusion chamber highly influence extrusion. Extrusion rate directly influences the surface quality of the final products. Abstract: Friction Stir Extrusion (FSE) is a novel process designed to directly recycle machining chips. An experimental campaign was carried out on AZ31 milling chips using variations in extrusion ratio, force and tool rotation rate. The process mechanics were studied and correlated to the material flow, which was elucidated through use of a copper marker. A 3D, Lagrangian, thermo-mechanically coupled dedicated numerical model was set up and validated through temperature measurements. The combination of experimental and numerical results permitted to reconstruct the complex 3D material flow induced by tool rotation and plunge into the extrusion billet chamber.