Effect of Die Material and Hardness On The Productivity of Copper Strips Via Hot Continuous Extrusion Process

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email:editoriijit@ipasj.org
ISSN 2321-6441
A Publisher for Research Motivation ........
Volume 4, Issue 8, August 2016
Effect of Die Material and Hardness on the

Productivity of Copper Strips via Hot
Continuous Extrusion Process
Alaa D. Yousif, Tawakol A. Enab*, Ahmed M. Galal , M. Samy El-Gayyar
Production Engineering and Mechanical Design Department, Faculty of Engineering, Mansoura University, P.O. 35516
Mansoura, Egypt.
ABSTRACT
Hot continuous extrusion is a widely forming process used in recent days, and it has a great progress. It's used for deforming
many non-ferrous metals especially aluminum and copper as well as their alloys. Many problems affect hot continuous
extrusion process such as machining parameters, die design, etc. The objective of this study is to investigate the influence of die
material and hardness on the productivity of copper strips using hot continuous extrusion process. Two hot work tool steel
materials (i.e. H10 and H13) and three hardness values (i.e. HRC40, HRC56 and HRC60) were applied for the dies used in the
experimental work. Results indicated that using H13 hot work tool steel is the best choice for extrusion die material, as well as
increasing die hardness leads to increase both die life and productivity.
Keywords: Hot continuous extrusion, Die material, Die hardness, Copper strips, Productivity
1. INTRODUCTION
Hot continuous extrusion is a widely used process for nonferrous fabrication. This process has many advantages such as
saving used energy and material, environmental friendly, etc. [1]. This process causes changes in metallurgical and
mechanical properties of the extruded products [2]. These products commonly involve aluminum, copper and their
alloys in the form of rods, tubes, wires, channels, etc. [1], [3].
Kumari et al. [2] investigated circular copper rods produced by hot continuous extrusion forming process. This
investigation includes microstructure analysis before and after deformation as well as extruded copper tensile and
hardness tests. This experimental study proved that fabricated copper rods by continuous extrusion machine leads to
produce uniform homogeneous grains. Moreover, this technique increases both the product tensile strength by 6.8%
and the breaking load by 22.9%.
Song et al. [3] made an experiment on Cu-Mg alloy shaped by hot continuous extrusion (conform process) to
investigate its structure. Conform process improved the homogeneity and refined the grain structure. However, this
technique generated dynamic re-crystallization. Peng et al. [4] carried out a three-dimensional finite element analysis to
investigate the influence of wheel angular velocity through continuous conform extrusion process to form copper
concave bus-bar. The numerical simulation showed that the deformation body flow velocity in the die orifice increased
with increasing the angular velocity of the extrusion wheel. Although with high velocities there were slippage between
the copper rod and the extrusion wheel which was improved close to the die orifice. Due to high deformation
temperature the process needs cooling to reduce friction. Low wheel velocity leads to lower yield efficiency, while high
velocity causes deformation and heat quantity increase.
An advanced technique in continuous extrusion was studied by Xu et al. [1]. This technique is extrusion process under
large expansion ratio of copper strips. A finite element method was used and showed that expansion ratio above 6
causes inhomogeneity metal flow in the width direction. A finite element analysis and an experimental study were
carried out by Stobrawa et al. [5] to investigate microstructure and mechanical properties of Cu-Ni2-Si strips produced
by continuous repetitive corrugation and strengthening. Strips samples were quenched or annealed as a part of the
experiment. Results showed a change in the product samples which reduced the grain size and made it fine especially
with the annealed samples. Also, the yield strength and the tensile strength increased especially with the quenched
samples.
Huang et al. [6] investigated the effect of die angle value on copper deformation via equal channel angular extrusion
(ECAE) process. The result showed that the produced deformation texture is similar to that of simple shear. This
deformation is uniform with ultrafine grain size. Qamar et al. [7] investigated experimentally the effect of various heat
treatment types on fracture toughness and hardness of AISI H13 (DIN 1.2344) steel used in hot and cold forming dies
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to produce Aluminum alloys products with hollow profile. First remove any preexisting anomalies of material
properties for all H13 samples by annealing cycle process. Then H13 samples were divided to two groups; single
tempering and double tempering. Results showed that toughness and hardness vary in nonlinear behavior with
tempering temperature. It has increasing-decreasing trend with hardness, while it has decreasing-increasing trend with
toughness. Therefore, the suitable tempering temperature is 525-550C which has high hardness and toughness.
Therefore, it is worth to note that, extruded copper has a great progress in recent days, but many problems appear
through its fabrication such as deforming mechanism, process parameters, die design, etc [1], [4]. The current study
focuses on the influence of both dies' material and dies' hardness on the productivity of hot continuous extrusion
process. Noting that the process productivity measured by the total weight and length of the produced copper strips
until the die failure.
2. EXPERIMENTAL PROCEDURES
Contact between metal and die through extrusion process causes die failure due to high temperature, high pressure and
friction of continuous hot extrusion process. This failure causes many problems; this leads to inaccurate extruded
product's dimensions and waste time for die maintenance or change that leads to increase cost.
Die material and die hardness are two crucial parameters which affect the productivity of hot continuous extrusion
process. Therefore, two types of materials were used to study the effect of die material on productivity of copper strips
via hot continuous extrusion process. Thus, hot work tool steel die materials H10 and H13 used in the current
investigation. Moreover, to investigate the effect of die hardness on productivity of copper strips, three different
hardness values for H13 die material (i.e. HRC40, HRC56 and HRC60) were used.
2.1. Copper feedstock
The feedstock is continuously fed into the extrusion wheel groove through a coining roll under high temperature and
pressure, and then the close fitting shoe closed the groove. The abutment prevents the feedstock from continuing its
passage around the wheel. The material is extruded and shaped out from special dies. This process is shown in Fig. (1)
[3], [8]. The feedstock is heated to a temperature of 800 C in a special oven before extruding. Machine control is
strapped to an electronically controlled computer which records all required data for each second. Recorded data are die
temperature, current, the machine rotational speed and the amount of production (total length and weight).
Pure copper feedstock (AMS4700: 99.99% Cu, oxygen-free; used in electrolytic works [9]) was used in the present
investigation. The feedstock is extruded via hot continuous extrusion process (Fig. 2).
Figure 1 Hot continuous extrusion process [3], [8].
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ISSN 2321-6441
Figure 2 Extruded copper strip sample via hot continuous extrusion process.
2.2. Extrusion Die
The hot work steel die has 80 mm outer diameter and 15 mm thickness. Inlet die orifice (feedstock copper) has 38*13
mm2 cross-section and the outer die orifice (extruded output strip) has 20*5 mm2 cross-section (Fig. 3).
Firstly, the used extrusion dies are made of AISI H10 (DIN 1.2365) and H13 (DIN 1.2344) hot work tool steel to
investigate the productivity of extruded copper strips. The two die materials have the same hardness HRC56. Table (1)
shows their chemical compositions [10], [11].
Secondly, the used extrusion die is made of AISI H13 hot work tool steel (DIN 1.2344). The experimental work was
carried out for three different dies' hardness, HRC40, HRC56 and HRC60, to investigate the productivity. The
difference in hardness is due to heat treatment of hot work H13 tool steel.
Figure 3 Inlet and outlet orifice of H13 hot work steel die used in hot continuous extrusion machine.
Table 1: Chemical compositions of AISI H10 and H13 hot work tool steel [10], [11].
AIS
I
H10
H13
Min. %
Max.
%
Min. %
Max.
%
Si
0.2
8
0.3
5
0.3
5
0.4
2
0.1
0
0.4
0
0.8
0
1.2
0
Mn
0.1
0.4
5
0.2
5
0.5
0
0.03
0
0.03
0
0.02
5
0.00
5
Cr
Mo
2.7
0
3.2
0
4.8
0
5.5
0
2.6
0
3.0
0
1.2
0
1.5
0
0.4
0
0.7
0
0.8
5
1.1
5
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ISSN 2321-6441
3. RESULTS AND DISCUSSION

3.1. Effect of Die Material
Experimental work indicated that, for the hot work H10 tool steel die with HRC56 hardness, die failure occurred after
90 min. The total production of extruded copper strip was 802.8 Kg weight and 685.5 m length approximately (Fig. 4).
While, for the hot work H13 tool steel die with HRC56 hardness, die failure happened after 130 min. Through these
130 minutes, the extrusion machine extruded approximately 1092 Kg weight and 917.5 m length of copper strip (Fig.
4).
Furthermore, the comparison between the two die materials; H10 and H13; showed that, H13 hot work tool steel die
leads to increase the die life more than H10. This increase causes an increment in the machine productivity for both the
extruded product's weight and length before die failure.
3.2. Effect of Die Hardness
Moreover, experimental work showed that, for H13 hot work tool steel with hardness of HRC40, HRC56 and HRC60
the die failure occurred after 105, 130 and 140 minutes respectively. Additionally, the total weights of extruded copper
strips were 850, 1092 and 1128.5 kg respectively using dies with the above mentioned three hardness values. On the
other hand, the total lengths of the extruded copper strips were approximately 690, 917.5 and 961.5 meter length (Fig.
5).
Comparison among the three hardness cases proved that, increasing the extrusion die hardness leads to an increment in
the die life. This will increase the machine productivity for both the product's weight and length before die failure.
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ISSN 2321-6441
4. CONCLUSION
In the current study, experimental work carried out using dies made from H10 and H13 hot work tool steel with HRC56
to investigate the effect of die material on productivity of copper strips produced by hot continuous extrusion process.
Moreover, three dies hardness (i.e. HRC40, HRC56 and HRC60 for H13 hot work tool steel) were tested to investigate
the effect of die hardness on the productivity.
The following points can be concluded:
6. H13 hot work tool steel die has the longer life and the maximum productivity of copper strips produced by hot
continuous extrusion process.
7. Die life and die productivity increased with the increment of the die hardness.
5. ACKNOWLEDGEMENTS
The authors would like to thank Egyptian- Germany Engineering Industrial Company and Egyptian Copper Works
Company for the patience, support and provision of research facilities used in this study.
References
[1] XB. Yun, ML. Yao, Y. Wu, BY. Song, "Numerical simulation of continuous extrusion extending forming under
the large expansion ratio for copper strip", Applied Mechanics and Materials, Vol. 80-81, PP. 91-95, 2011.
[2] S. Kumari, A. K. Rai, D. K. Sinha, R. C. Francis, "Deformation behavior and characterization of copper alloy in
extrusion process", International Journal of Mechanical Engineering and Technology IJMET, Vol. 6, Issue 7, PP.
72-78, July 2015.
[3] L. Song, Y. Yuan, Z. Yin, "Microstructural evolution in Cu-Mg alloy processed by conform", International Journal
of Nonferrous Metallurgy IJNM, Vol. 2, Issue 3, PP. 100-105, 2013.
[4] PY. Wu, SS. Xie, HQ. Li, M. Yan, GJ. Huang, L. Cheng, "Effect of extrusion wheel angular velocity on continuous
extrusion forming process of copper concave bus bar", Transactions of Nonferrous Metals Society of China, Vol.
17, Issue 2, PP. 280-286, 2007.
[5] J. Stobrawa, Z. Rdzawski, W. Guchowski, W. Malec, "Microstructure and properties of CuNi2Si1 alloy processed
by continuous RCS method", Journal of Achievements in Materials and Manufacturing Engineering, Vol. 37, Issue
2, PP. 466-479, 2009.
[6] W.H. Huang, L. Chang, P.W. Kao, C.P. Chang, "Effect of die angle on the deformation texture of copper processed
by equal channel angular extrusion", Materials Science and Engineering A, Vol. A307, PP. 113-118, 2001.
[7] S.Z. Qamar, A.K. Sheikh, A.F.M. Arif, T. Pervez, R.A. Siddiqui, "Heat treatment of a hot-work die steel",
Archives of Materials Science and Engineering, Vol. 28, Issue 8, PP. 503-508, 2007.
[8] http://www.hormesa.com, [Accessed: May 2016].
[9] Continuous Extrusion Production Line for Copper Flat Wire and Copper Bar, http://www.fareastmachinery.com,
[Accessed: May 2016].
[10] Gloria Material Technology Corp., Alloy Steels SNCM439, http://www.gmtc.com.tw, [Accessed: May 2016].
[11] http://ozct.com.tr/en/pdf/1.2344 X40CrMoV5-1.pdf, [Accessed: May 2016].
AUTHORS
Alaa D. Yousif received the B.S. degrees in Mechanical Engineering from University of Anbar,
Iraq in 2003. During 2006-2013, he stayed in Shaheed State Company, Ministry of Industry and
Minerals, Republic of Iraq. He is now studying M.Sc. at Production Engineering and Mechanical
Design Department, Faculty of Engineering, Mansoura University, Mansoura, Egypt. His research
title: Effect of Die Material and Hardness on the Productivity of Copper Strips via Hot Continuous
Extrusion Process.
Tawakol A. ENAB graduated from Faculty of Engineering, Mansoura University, Egypt in 1995
and received the Ph. D. degree from Savoie University, Chambery, France in 2004. Currently, he is
an Associate Professor at Production Engineering and Mechanical Design Department, Faculty of
Engineering, Mansoura University, Mansoura, Egypt. His research interests comprise: the
mechanical behavior of advanced composite materials, piezoelectric composites, functionally graded
materials, biomaterials, biomechanical performance of human joints (knee and hip) and simulation
of forming and machining processes.
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Ahmed M. Galal graduated from Faculty of Engineering, Mansoura University, Egypt, 1991. M.
Sc. Production Engineering, Mansoura University, Egypt, 2002. Thesis topic: "Computer Aided
Simulation for the Performance of Plastic Extruder Screw". From January 2015 till now: Associate
Professor, Prod. Eng. & Mech. Design Dept., Faculty of Engineering, Mansoura University, Egypt.
Gained Doctoral Degree from Kyushu Institute of Technology, Japan at 25/3/2009. Thesis topic:
"Proposal of Unique Wind Power Unit".
M. Samy El-Gayyar graduated from Faculty of Engineering, Mansoura University, Egypt in 1977
and received the Ph. D. degree from Mechanical Faculty, Technical University, Bratislava, Slovakia,
in 1996. Currently, he is an Emeritus Professor at Production Engineering and Mechanical Design
Department, Faculty of Engineering, Mansoura University, Egypt. His research interests comprise:
Application of Artificial Intelligence Techniques in the Field of Mechanical Design and
Mechanisms, Structural Synthesis and Enumeration of Mechanisms and Epicyclic Gear Trains,
Graphical Coding, and industrial Safety and firefighting.
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IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation ........

Volume 4, Issue 8, August 2016