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Determining RAM Speed and Billet Temperature to Ensure Two Indicators of

Surface Roughness and Extrusion Pressure When Extruding Aluminum Alloy:
Proceedings of the International Co...

Chapter · January 2019

DOI: 10.1007/978-3-030-04792-4_34

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 Determining RAM Speed and Billet
Temperature to Ensure Two Indicators
of Surface Roughness and Extrusion Pressure
When Extruding Aluminum Alloy

Nguyen Trong Mai1(&), Do Duc Trung1, Tran Duc Quy1,

and Pham Van Nghe2
1
Hanoi University of Industry, Hanoi, Vietnam
trongmai85@gmail.com, dotrung.th@gmail.com
2
Hanoi University of Science and Technology, Hanoi, Vietnam

Abstract. The paper presents a study to determine the RAM speed and billet
temperature to ensure that both the surface roughness of aluminum alloy bars
and the extrusion pressure are the smallest. The RAM speed and billet tem-
perature are the main parameters that influence the surface roughness and
extrusion pressure when extruding aluminum bars. Product surface roughness is
an important indicator of the quality of extruded aluminum alloy bars. Extruded
pressure affects the machine’s performance and die life. By the theory of
experimental combination, the authors built regression function showing the
relationship between surface roughness, extrusion pressure with RAM speed and
billet temperature. Using the optimization method of two indicators, the author
has determined the RAM speed and billet temperature to achieve the surface
roughness of the aluminum alloy bar product, where extrusion pressure is
minimal. The results of this paper can be applied to determine the RAM speed
and billet temperature in aluminum alloy extrusion factories.

Keywords: Extrusion pressure
Surface roughness
Ram speed

Billet temperature
Aluminum alloy extrusion

1 Introduction

The extrusion pressure affects the elastic deformation of the die which in turn affects
the quality of the product and the life of the die [1–3, 6].
Surface roughness is an important criterion for the quality of aluminum alloy bar
during extrusion. It affects the workability as well as the aesthetics of the aluminum
alloy bar [2, 4, 5].
There are many factors that influence the surface roughness of aluminum alloy bars
and extrusion pressure, such as direct extrusion or indirect extrusion, billet material,
billet temperature, RAM speed, extrusion ratio, friction, die design… [2, 3].
The effect of extrusion temperature to the product surface roughness is shown in
[4, 5]. The effect of billet temperature on extrusion pressure is also presented in [2, 6].
Beside billet temperature, RAM speed also affects the temperature of the extrusion

© Springer Nature Switzerland AG 2019

H. Fujita et al. (Eds.): ICERA 2018, LNNS 63, pp. 253–260, 2019.
https://doi.org/10.1007/978-3-030-04792-4_34
254 N. T. Mai et al.

process, [2] affecting the surface roughness and extrusion pressure. However, the
simultaneous influence of two parameter billet temperature and RAM speeds on alu-
minum alloy surface roughness and extrusion pressure has not been investigated.
Therefore, it is necessary to conduct studies and experiments to find the relationship
between two parameters of RAM speed and billet temperature to the surface roughness
of the product and extrusion pressure. Using the two-target optimization method to
determine the RAM speed and billet temperature to achieve the surface roughness of
the product, the pressing pressure is minimal (Fig. 1).

Fig. 1. Tooling configuration in direct extrusion processing with a solid die [2].

2 Experiment

2.1 Experiment Conditions

The profile aluminum extrusion products of experiments is shown in Fig. 2.

Scontainer
Extrusion ratio K ¼ ¼ ð3,14  90  90Þ=ð3,14  70  5  1Þ ¼ 23 ½2 ð1Þ
Sprofile
N

Fig. 2. Profile of aluminum bar for experiment

 Determining RAM Speed and Billet Temperature 255

Where: K is the extrusion ratio, Scontainer is the area of container (the diameter of the
container is Ø180 mm), Sprofile is the area of product section and N is the number of
symmetrical holes (N = 1).

Table 1. Chemical composition of billet [2, 3]

Billet Chemical composition
Si Fe Cu Mn Mg Cr Zn Other
Al-6061 0,6 0,7 0,3 0,15 0,8 0,15 0,25

Billet of the experiment: the diameter of Ø180 mm, the length of 500 mm and the
material of Al-6061 with chemical composition is mentioned in Table 1.

Fig. 3. Simulation extrusion test with Qform extrusion

Extrusion Die Experiment: Extrusion Die is designed to ensure a metal flow balance
[7–9] and is tested by Qfrom extrusion simulation software [14] as shown in Fig. 3,
then manufacturing extrusion die for the experiment as shown in Fig. 4.
Direct extruder machine: SAMWOO at Huyndai aluminum Vina factory (Fig. 5),
extruded pressure display on the machine’s control panel.
Mitutoyo Surftest SJ-400 machine (Fig. 6). The surface roughness of the aluminum
bar product was measured on the Mitutoyo Surftest SJ-400 machine. The specification
is as follows: Evaluation criteria ISO, standard length 0,8 mm, stylus type diamond,
contact measurement, press: 0,75 N, speed: 0,05 mm/s.
256 N. T. Mai et al.

Fig. 4. Extrusion Die for experiment

Fig. 5. Direct extruder machine Fig. 6. Mitutoyo SJ-400 machine

SAMWOO

2.2 Experiment Method

The relationship between surface roughness (Ra), extrusion pressure (P) with RAM
speed (Vep) and billet temperature (Tp) is determined by the function:


Ra ¼ f Vep ; Tp ð2Þ


P ¼ f Vep ; Tp : ð3Þ
 Determining RAM Speed and Billet Temperature 257

The experiment is conducted with various RAM speeds and billet temperatures
according to the 2k form experiment matrix, and experiment sites are added at the
center. With the number of input variables k = 2, the number of main experiments
n = 2k = 22 = 4, the number of experimental center points is 2 [11]. All experimental
points are 6.
Based on the specification of the direct extruder machine and the permissible limits
of aluminum alloy extrusion, RAM speed and billet temperature are chosen in the
following defined region: [2]
Ram speed: 4  Vep  6 mm/s; Billet temperature: 420  Tp  470 °C.
Experimental parameters are shown in Table 2.

Table 2. Result of experiment

No. Coding Varient Roughness Extrusion pressure
variant
X1 X2 Vep (mm/s) Tp (oC) Rz (µm) P (N/cm2)
1 −1 −1 4 420 20,3 207
2 1 −1 6 420 18,5 210
3 −1 1 4 470 15,9 198
4 1 1 6 470 17,8 202
5 0 0 5 445 17,3 204
6 0 0 5 445 17,3 205

At points of the experiment after extrusion, the surface roughness test is conducted
and the results of extrusion pressure on the machine are recorded. After the results of
the experiment, data processing was performed to find the equation for the relationship
between surface roughness, extrusion pressure with RAM speed and billet temperature.
Using the multi-objective optimization algorithm to find the RAM speed and billet
temperature to achieve the surface roughness of the product, the pressing pressure is
minimal.

3 Result of Experiment

Convert the experiment variables from nature to dimensionless coding variables. The
experimental results in Table 2, the experimental samples are shown in Fig. 7.
From the data in Table 2, the authors constructed a regression function that shows
the relationship between surface roughness, extrusion pressure with RAM speed and
billet temperature according to Eqs. (2) and (3) by Software Excel as follows:

Rz ¼ 17; 3 þ 0; 025x1  1:275x2 þ 0; 825x21 þ 0; 925x1 x2 ð4Þ

P ¼ 204; 5  1; 75x1  4; 25x2  0:25x21 þ 0; 25x1 x2 ð5Þ

258 N. T. Mai et al.

Fig. 7. Workpieces of experiments

Equations (4) and (5) serve as the basis for determining the value of RAM speed
parameters and billet temperature to ensure surface roughness and extrusion pressure.
Determine the parameters Vep and Tp to ensure the two indicators Rz and P
simultaneously.
Applying the multi-objective problem solving method derived from Eqs. (4) and
(5) determines the ramp and billet temperature to ensure the simultaneous measurement
of Rz and P. According to the documents [13], the surface roughness of the extruded
aluminum alloy rod generally requires Rz  20 lm. At the same time, the extrusion
pressure of the Direct extruder machine SAMWOO must ensure P  230 (N/cm2),
and this is the domain defined for the output parameters. Then, the multi-objective
optimization problem is written in the form of the encoding of the input parameters as
follows: [12]
8
>
> Rz ! min
>
>
< P ! min
1  x1 ; x2  1 ð6Þ
>
>
>
> 0\Rz  Rz ¼ 20
:
0\P  P ¼ 230

There are many methods for solving multi-objective optimization problems such as
total ratio method, multiplier ratio method and average harmonic method. In this study,
with two targets not in the same dimension (Rz and P) the total ratio method is applied,
then expression (6) is written as a multipoint function as follows:
8 Rz P
< Y ¼ w1 Rz þ w2 P ! min
>
1  x1 ; x2  1 ð7Þ
>
: 0  w1 ; w2  1
w1 þ w2 ¼ 1
 Determining RAM Speed and Billet Temperature 259

In the expression (7), w1 and w2 are respectively the ratio of Rz and P. The value
of w1 and w2 depends on the specific requirements of each type of product. In this
study, w1 and w2 were chosen to be equal, ie w1 = w2 = 0.5.
Using the Solve tool in software Excel to solve the Eq. (7) with a generalized
gradient reduction algorithm, the authors receive the values of the variables in encoded
form as x1 = −0,51 and x2 = 1. The actual values of the parameters of the corre-
sponding technology is: Vep = 4,49 (mm/s), Tp = 470 °C. The two indicators Rz and
P have respective values of Rz = 15,75 (lm), P = 200,95 (N/cm2).

4 Summary

Based on empirical research, a regression function was developed to show the rela-
tionship between surface roughness, extrusion pressure with RAM speed and billet
temperature, respectively:

Rz ¼ 17; 3 þ 0; 025x1  1:275x2 þ 0; 825x21 þ 0; 925x1 x2

P ¼ 204; 5  1; 75x1  4; 25x2  0:25x21 þ 0; 25x1 x2

Based on that, the values of the RAM speed and billet temperature parameters were
determined to ensure that both the surface roughness index of the extruded product and
the extrusion pressure were the smallest: Vep = 4,49 (mm/s) and Tp = 470 °C with Rz
and P having respective values of Rz = 15,75 (lm), P = 200,95 (N/cm2).

Acknowledgements. The author thanks the help of Hyundai Aluminum Vina factory and
EUROHA Alumium factory during experiments of this paper.

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