Theoretical analysis of extrusion of rectangular, hexagonal and octagonal composite clad rods

Composite clad rods with non-axisymmetric cross-sectional areas are commercially important owing to their extensive industrial applications such as in electrodes, conductors and chemical devices. For instance, in the processing of superconductor wire, increasing the packing density involves closely packing superconductor rods which have a hexagonal cross-section next to each other inside the high purity copper tube. During extrusion process, non-uniform deformation tends to occur because the core and sleeve of a composite clad rod is usually composed of materials with different mechanical properties. The first recognized paper on round-to-square drawing/extrusion with variable corner radius was presented by Boer et al. in 1979. In this study, we present a model based on upper-bound theorem to analyze the extrusion of composite clad rods with non-axisymmetric cross-section. Velocity fields for both core and sleeve are generated with the assistance of a productʹs cross-sectional profile functions. Products with rectangular, hexagonal and octagonal sections are chosen as the study objects. Also discussed herein are numerical results for various process variables such as semi-die angle, reduction of area, frictional condition of die, and product shape complexity. According to these results, the extrusion pressure and product dimensional change are closely related to the process variables.