Selection of Optimal Tool Geometry for the Production of Brass Wires Using the FSBE Method

Journal of Solid Mechanics

مقاله 5، دوره 15، شماره 1، خرداد 2023، صفحه 66-77   

نوع مقاله: Research Paper

شناسه دیجیتال (DOI): 10.22034/jsm.2021.1938200.1714

نویسندگان

M Akbari^{* 1}؛ P Asadi²؛ H Rahimi Asiabaraki¹

¹Department of Mechanical Engineering, Technical and Vocational University (TVU),Tehran, Iran

²Department of Mechanical Engineering, Faculty of Engineering, Imam Khomeini International University, Qazvin, Iran

چکیده

This research studied different tools with different cone angles to produce brass wires using the friction stir back extrusion (FSBE) method. The cone angle of the tool is one of the most influential parameters in the production of brass wires. First, to determine the appropriate cone angle, the FSBE process is modeled using the Coupled Eulerian-Lagrangian (CEL) method. The simulation results showed that increasing the cone angle increases the heat generated and reduces the force on the tool. Also, to be more precise, the mechanism of heat production during the process was numerically modeled to verify the simulation results. The cross-sectional images of the wires produced showed that only tools with a cone angle of 35 ° could produce flawless wires. The microstructural results showed that the grain size in the center of the wire was 20.24 microns, which is larger than the size in the wire periphery, which was 16.88 microns. This microstructural deviation is mainly affected by the strain and the temperature.

کلیدواژه‌ها

FSBE؛ Recycling؛ Microstructure؛ FEM؛ Cone angle

مراجع

1. Heidarzadeh A., 2020, Application of nanoindentation to evaluate the hardness and yield strength of brass joints produced by FSW: microstructural and strengthening mechanisms, Archives of Civil and Mechanical Engineering 20(2): 41.
2. Heidarzadeh A., 2019, Tensile behavior, microstructure, and substructure of the friction stir welded 70/30 brass joints: RSM, EBSD, and TEM study, Archives of Civil and Mechanical Engineering 19(1): 137-146.
3. Xu N., 2020, Recrystallization of Cu-30Zn brass during friction stir welding, Journal of Materials Research and Technology 9(3): 3746-3758.
4. Saravanakumar S., 2020, Experimental analysis of dissimilar metal of copper and brass plates fabricated friction stir welding, Materials Today: Proceedings 33: 3131-3134.
5. Evans W.T., 2015, Friction stir extrusion: a new process for joining dissimilar materials, Manufacturing Letters 5: 25-28.
6. Buffa G., 2016, AZ31 magnesium alloy recycling through friction stir extrusion process, International Journal of Material Forming 9(5): 613-618.
7. Akbari M., Asadi P., 2020, Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian–Lagrangian method with experimental verifications, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 234(8): 1117-1128.
8. Akbari M., Asadi P., Behnagh R.A., 2021, Modeling of material flow in dissimilar friction stir lap welding of aluminum and brass using coupled Eulerian and Lagrangian method, The International Journal of Advanced Manufacturing Technology 113(3): 721-734.
9. Akbari M., 2017, Hybrid multi-objective optimization of microstructural and mechanical properties of B4C/A356 composites fabricated by FSP using TOPSIS and modified NSGA-II, Transactions of Nonferrous Metals Society of China 27(11): 2317-2333.
10. Tahmasbi K., Mahmoodi M., 2018, Evaluation of microstructure and mechanical properties of aluminum AA7022 produced by friction stir extrusion, Journal of Manufacturing Processes 32: 151-159.
11. Li J., 2021, Friction stir extrusion for fabricating Mg-RE alloys with high strength and ductility, Materials Letters 289: 129414.
12. Baffari D., 2017, Process mechanics in Friction Stir Extrusion of magnesium alloys chips through experiments and numerical simulation, Journal of Manufacturing Processes 29: 41-49.
13. Asadi P., Akbari M., 2021, Numerical modeling and experimental investigation of brass wire forming by friction stir back extrusion, The International Journal of Advanced Manufacturing Technology 116: 3231-3245.
14. Akbari M., Asadi P., 2021, Optimization of microstructural and mechanical properties of brass wire produced by friction stir extrusion using Taguchi method, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 235(12): 2709-2719.
15. Meyghani B., 2017, A comparison of different finite element methods in the thermal analysis of friction stir welding (FSW), Metals 7: 450.
16. Chakrabarty R., Song J., 2020, A modified Johnson-Cook material model with strain gradient plasticity consideration for numerical simulation of cold spray process, Surface and Coatings Technology 397: 125981.
17. Balu Mahandiran M., 2021, Investigation of solid state welding of copper nickel alloy (Cu-Ni 90/10) using FSW process, IOP Conference Series: Materials Science and Engineering 1145(1): 012112.
18. Wang X., 2020, On the solid-state-bonding mechanism in friction stir welding, Extreme Mechanics Letters 37: 100727.
19. Schmidt H., Hattel J.H., Wert J., 2003, An analytical model for the heat generation in friction stir welding, Modelling and Simulation in Materials Science and Engineering 12: 143.
20. Akbari M., 2016, The effect of in-process cooling conditions on temperature, force, wear resistance, microstructural, and mechanical properties of friction stir processed A356, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials Design and Applications 232(5): 429-437.
21. Akbari M., 2015, Investigation of the effect of friction stir processing parameters on temperature and forces of Al–Si aluminum alloys, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 232(3): 213-229.