Prediction of temperature evolution during the extrusion of 7075 aluminium alloy at various ram speeds by means of 3D FEM simulation

In the present work, an attempt was made to predict the temperature evolution during the extrusion of 7075 aluminium alloy by means of 3D FEM computer simulation. Results show that ram speed has a significant influence on the temperature distribution in the billet, which continuously changes throughout the process, as a result of complex heat generation and heat loss. The thermal effect results in characteristic variation of extrusion pressure. At a higher ram speed, the decrease of extrusion pressure is faster during the steady-state extrusion, due to more heat generation, less heat loss and thus more steeply decreased flow stress, as the process proceeds. The temperature inhomogeneity on the cross-section of the workpiece entering the die bearing is more pronounced when ram speed is higher. While going through the die, the extrudate undergoes a process of temperature redistribution and the temperature becomes more homogeneously distributed at the die exit. The present simulation does not render support to the general statement that the corner of the extrudate is hotter than the flat surfaces. Incipient melting is predicted to occur after a half of the billet is extruded at a ram speed as low as 1 mm/s corresponding to an extrusion speed of 0.48 m/min, if the billet contains the phases with low melting points. However, if the billet of the same alloy is in an improved metallurgical condition, no melting-related defects would be expected to occur to the extrudate running at a speed eight times faster. The results also confirm the linear relationship between the increase of the maximum temperature and logarithmic ram speed during the steady-state extrusion.