NUMERICAL MODELLING AND OPTIMIZATION OF

EXTRUSION PARAMETERS FOR BIMETALLIC

EXTRUSION OF Ti6Al4V AND AZ31B ALLOYS
ROHITH ROSHAN B.R 1, ARAVIND M 2, SRIRAM S3, GAJANAND D 4, and C.S
SUMESH5
1,2,3,4,5
Dept. of Mechanical Engineering, Amrita school of Engineering, Coimbatore, Amrita
Vishwa Vidyapeetham, India
1E-mail: rohithmi10@gmail.com, 2E-mail: aravind.mahadevan 01@gmail.com, 3E-mail:

sriramneyveli18@g mail.com, 4E-mail: gajdhina@hotmail.com, 5E-mail: cs_sumesh@cb.amrita.edu,

ABSTRACT: In this work ABAQUS/Explicit FE package is used to create a numerical model

replicating Bimetallic extrusion process of Ti-6Al-4V and AZ31B alloys. A detailed FE model was
developed and validated by comparing the results with an existing literature. Response Surface
methodology (RSM) was used to formulate the objective function and obtain optimum extrusion
parameters, in DoE software. The influence of each extrusion parameters on extrusion force was
studied with the help of ANOVA and significance and contribution of each parameter were identified.
From ANOVA, it is concluded that billet height, die angle and co efficient of friction are the most
significant parameters influencing extrusion force. Also, from the study it was found that extrusion
force increases with increase in billet height, die angle and coefficient of friction. and decreases with
increase in ramp speed, core diameter and initial billet temperature. Finally, simulation was run using
the optimized extrusion parameters and extrusion force obtained from the simulation was compared
with the predicted value. The error percentage was found to be less than 1%.

KEYWORDS: Bimetallic Extrusion, Ti6Al4V, AZ31B, Response Surface Methodology, ANOVA

INTRODUCTION
Bi-metallic extrusion is a metal forming process
in which an initial billet is made up of two separate metallic Al/Cu rod is 30-40% less expensive than
metallic materials that are cold extruded together at pure Cu rod while performing the same function.
the same time. This produces a final product with
various qualities (mechanical, electrical, thermal,
magnetic, frictional, etc.) at various workpiece
portions. This type of metal forming allows for the
fabrication of workpieces with the best possible
combination of desired attributes, which are then
combined into the final product.
Fig. 1 Bimetallic cylinder sketch (Fernández D
2021)
Many theoretical and practical investigations
have been undertaken in recent years as a result of
the growth of applications employing bi-material
extruded products. Bi-material items that have been
properly created have an ideal combination of
required features while minimizing their limiting
properties. According to (Plancak Met. al 2012) bi-
The number of metal combinations that can be used
in bi-metallic extrusion is rather vast, allowing for
numerous possibilities in this procedure. Although
bi-metallic components have a limited industrial
application, current research and development
successes in this forming alternative point to a wider
commercial implementation in the near future.
Several research projects have combined
magnesium alloys with other lightweight alloys, such
as aluminium alloys. (Negendanka et. al. 2012),
looked into the effect of die angle on diffusion layer
generation during coextrusion of Mg-core and Al-
sleeve. Typically, the co-extrusion method is utilised
to create multi-material cylinders that will be used as
billets to make complex shape components. Because
of the high pressures and temperatures generated at
the interface of both materials due to plastic
deformation and diffusion processes, this is an
extremely complicated thermo-mechanical process.
Several studies have been conducted involving the
use of magnesium alloys in conjunction with other
lightweight alloys, such as aluminium alloys.
(Thirumurugan et al. 2011) conducted research on the
manufacture of a ZM21 magnesium alloy/CP
aluminium alloy utilising direct hot co-extrusion with
three variable extrusion ratios while maintaining
constant temperature and ram speed. (Fernández et al.
2020) that determined the most relevant parameters to
reduce the extrusion force during a co-extrusion
process of bimetallic AZ31B-Ti6Al4V billets. (Gall
et al. 2009) used FEM simulations to generate hollow
profiles from bimetallic Al-Mg billets during the co-
extrusion process. Unfortunately, few research have
combined such disparate metallic alloys in terms of
density, yield strength, or elastic modules, such as
Titanium and Magnesium alloys. For two types of
moulds with conical and curved geometry, finite
element simulation was used to investigate the effect
of angle, coefficient of friction, and internal profile of
the mould on the extrusion force and dimensional
uniformity of the produced parts during the extrusion
of copper and aluminium in cylindrical forms
(Kordeyazdi, Met. al. 2021). The importance of
various parameters during indirect extrusion of
copper-clad aluminium (CCA) rods was examined
using statistical methods and a central composite
experimental design (Lechner S et. al. 2021).
FE simulations were used to investigate the
distribution of damage factor during the extrusion
process and how manufacturing parameters
(extrusion ratio, friction, and die semi-angle)
influence this factor and the extrusion force during an
extrusion process to manufacture bimetallic cylinders
combining a titanium alloy sleeve (Ti6Al4V) and a
magnesium alloy core (AZ31B) (D Fernández et
al 2021). (Fernández D 2021) developed an efficient
finite element model to explore variation in extrusion
force, damage distribution, and wear of bimetallic
extrusion of cylindrical billets combining a
magnesium alloy core (AZ31B) and a titanium alloy
sleeve (Ti6Al4V) of interest in aeronautical
applications. A combined numerical-experimental
technique is used to investigate the impact of the
center-ring form factor and type of assembly fit
(interference and clearance), as well as the effect of
friction on compression force and ductile damage.
(Camacho AM et. al. 2019). Unfortunately, there are
few studies that combine different metallic alloys in
terms of density, yield strength, or elastic modules,
such as Titanium and Magnesium alloys, such as
(Behrens B A et. al. 2018) study of semi-finished
products made of aluminium and steel and
manufactured using the lateral angular co-extrusion
process.
The state of the equipment, the working
conditions, the temperatures, the pressures, the die
quality, and the materials used are all important
factors. The purpose of this research is to find out how
different aspects affect product quality and to come
up with a set of guidelines for optimizing the
bimetallic extrusion process. Provide an optimal
parameter set for enhancing the bimetallic extrusion
process.
From the literature review conducted, it was
observed that not many researchers had done
optimization of extrusion parameters to minimize the
extrusion force. So in this work a finite model was
developed to simulate the bimetallic extrusion of
Titanium (TiAl4V6) and Magnesium (AZ31B). Later
this model was compared with an already published
literature for model validation. After validating the
model, for the selected levels of extrusion
parameters, using DoE software, trails were
generated for optimization. Simulations were run for
these trails and extrusion forces are noted for each
trial. Then optimum values of extrusion parameters
were identified for minimum extrusion force. Then
simulation was run on these optimized values and
compared predicted and simulated values. It was
found that predicted and simulated values are in close
agreement, means the model developed can be used
to predict the extrusion forces accurately for the
Bimetallic extrusion process.
2. FINITE ELEMENT MODELLING OF
BIMETALLIC EXTRUSION PROCESS
Abaqus Explicit, a finite element software was used
in this work to develop the numerical model. In this
Finite Element Model, Titanium (Ti6Al4V) is
considered as sleeve and Magnesium (AZ31B) as
core. Both are modelled as deformable bodies in the
model. The material properties of core and sleeve
used in the model are given in Table 1. Flow stress
values of Magnesium AZ31B are given in Table 2.
The flow stress values of titanium are taken from
DEFORM software (Scientific Forming
Technologies 2017). Die and ram is modelled as an
analytical rigid. In the assembly module all parts,
die, ram, core and sleeve are arranged coaxially as in
figure 2. In the step module, dynamic explicit
analysis was selected. ALE was used in the model to
mesh the components with mesh size of 0.7. The
boundary conditions utilized in the load module are,
ENCASTRE is used on the reference point (RP)
created on the die, On the billets, displacement and
velocity boundary conditions are utilized. Tie
constraints were placed between the sleeve and core
surfaces, as well as between the billet top and ram
surfaces, and rigid body constraints were added to
the die and ram. C3D8T element type was used in
model with hex meshing on the billet. Initially mesh
convergence study was conducted to arrive at a
suitable mesh size.
Table1. Properties of Sleeve and Core 2.1 Validation of Numerical Model Developed
Property AZ31B TiAl4V The developed model is validated with an already
Density (g/cm3) 1.74 4.46 published literature, Fernández Martín, D., et al.
Tensile strength (MPa) 260 >895 (2020). In the developed model, the dimensions of
Yield strength (MPa) 200 >828 core and sleeve are used same as the values given in
Elastic modulus (MPa) 44.80 105-120 the paper. Figure 4 (a) and (b) shows the stress
Poisson’s ratio 0.35 0.31 distribution in the core and sleeve at temperatures
1500C. Figure 5 shows the variation of stress
distribution in core and sleeve.
Table 2. Flow curve stress values of AZ31B at
different temperature for a strain rate of 0.001
Stress (Mpa)
Strain T= T= T= T=
150oC 200oC 250oC 300oC
0.02 112.69 91.54 74.35 60.4
0.05 133.12 107.86 87.40 70.82
0.10 168.45 136.07 109.91 88.78
0.15 202.14 163.00 131.44 105.99
0.20 230.06 185.44 149.47 120.49
0.25 248.31 200.35 161.65 130.42
0.30 254.18 205.56 166.23 134.43
(a) (b)
Fig. 4 Stress Contours of Core and Sleeve when T
=150℃ (a) inside view (b) outside view

(a) core (b) sleeve

Fig. 5 Variation of Extrusion force versus time

Figure 6 shows the comparison of extrusion force
obtained from the developed model and the values
obtained from the paper Fernández Martín, D., et al.
(2020). It was found that results obtained from the
model is well matching with results in the validation
paper.

(c) Die (d) Assembly

Fig. 2. Different Parts in the Model and Assembly

Fig. 3. Mesh of Core and Sleeve Fig. 6 Comparison of Extrusion Force

3. OPTIMIZATION OF EXTRUSION Table 4. Value of parameters for different levels
PROCESS PARAMETERS USING Parameter level 1 level 2 level 3
RESPONSE SURFACE METHODOLOGY Core diameter(mm) 5 6 7
(RSM)
The response surface methodology (RSM) is a widely Billet height(mm) 15 20 25
used mathematical and statistical tool for modelling Ram speed(mm/s) 1.5 2 2.5
and analyzing a process in which several variables
Temperature(0C) 150 200 250
influence the desired response with the goal of
optimizing it. In this work, initial trials were created Coefficient of friction 0.065 0.1 0.135
using a three-level, central composite face-centered 0
Die angle ( ) 30 45 60
design. All interactions were taken into account, and
no further repetitions were offered. To determine the
correct response value, the validated numerical model
developed in ABAQUS is used to replicate the 3.1 Analysis of Variance (ANOVA)
extrusion condition indicated in the trials generated Using RSM a mathematical model was developed
(Extrusion Force). The result was examined with a 95 and its significance was revealed by ANOVA. From
percent alpha value. Table 3 also shows the extrusion the ANOVA analysis shown in Table 4, the
force values achieved for each extrusion conditions. interactions terms having P-value more than 0.05 are
Table 4 shows the parameter values for different considered non-significant factors and removed from
levels. the analysis. After removing the non-significant
Table 3. Trials using RSM and Force Values terms, ANOVA was performed again and the final
Extrusion regression equation isobtained. R2 value will always
Parameter force lies between +1 and -1. If the value of R2 is close to 1,
Ram speed (mm/s) lvl 1 lvl 2 lvl 3 means the response variable is very closely related to
1.5 239.353 386.893 704.342 input parameters. Hence the model can be used to
2 239.101 383.479 813.164 predict the values of output parameters.
2.5 239.097 386.567 646.0415 ANOVA was done for extrusion force. The
3 239.115 386.843 665.979 predicted R-squared value of 98.80% is in good
Temperature settlement with adjusted R squared value of 97.71%.
The normal probability graph of residuals for
(degree C) lvl 1 lvl 2 lvl 3
extrusion force was plotted in Fig 7. In this plot,
150 239.353 435.969 816.954 residuals are close to the straight line, which means
200 209.456 383.479 731.101 the residuals are normally distributed. From the
250 198.361 363.736 646.0415 standardized residual plot shown in Fig 7, the
300 195.92 341.281 630.624 residuals are dispersed in both +ve and –ve directions
Die angle(degree) lvl 1 lvl 2 lvl 3 and do not show any obvious design. This suggests
30 239.353 345.06 458.603 that, model is acceptable. And also, there is no cause
45 307.734 383.479 543.244 to uncertain any violation of the independence or
60 352.216 473.784 646.0415 constant variance assumptions.
Cof lvl 1 lvl 2 lvl 3 Table 5. ANOVA for Extrusion Force
0.065 239.353 326.175 444.712 Source DF Adj SS Adj F- P-
0.1 274.551 383.479 584.335 MS Value Value
0.135 310.551 432.67 646.0415 Model 18 7.79592 0.433107 245.37 0.000
Linear 6 3.42401 0.570669 323.31 0.000
0.175 347.186 495.115 804.577 Core 1 0.00758 0.007575 4.29 0.047
Billet height(mm) lvl 1 lvl 2 lvl 3 diameter
15 239.353 270.123 381.375 Billet 1 0.84012 0.840121 475.96 0.000

20 340.07 383.479 537.33 height

Ram speed 1 0.00399 0.003990 2.26 0.144
25 439.428 490.026 646.0415 Temp 1 0.11984 0.119836 67.89 0.000
Core diameter(mm) lvl 1 lvl 2 lvl 3 Cof 1 0.52180 0.521796 295.62 0.000
5 239.353 402.007 709.604 328.91 0.000
Die angle 1 0.58055 0.580553
6 229.433 383.479 703.785 Error 29 0.05119 0.001765 * *
7 203.819 364.146 646.0415 Total 47 7.84711 * * *
 Figure 8 shows the Pareto chart, which was used to
identify which parameter is the most influencing one.
From the chart it was found that billet height and die
angle are the most influencing parameter.
The main effects plot for extrusion force (Fig.9)
shows the trend ofthe response through the levels of the
six extrusion parameters
Fig. 7 Residual Plots for Extrusion Force (kN)
Fig. 8 Pareto Chart
From the plot (Fig. 9) it can be understand that,
extrusion force increases with increase in billet height,
Die angle and Coe. of friction. For the increase in
temperature, core diameter and ram speed, the
extrusion force decreases. According to previous
research, extrusion force decreases with ram speed due
to increase in strain rate sensitivity. Initially the billet
gets compressed to the size of the container, before
getting extruded. Also, initially static friction exists
between billet and container. As a result, there will be
slight increase in temperature so the extrusion force
decreases narrowly as shown. Increase in temperature
reduces the stress necessary to deform the billet thus,
the extrusion force is lower and it is typically used to
increase the formability of these materials. The ring
and core were built with an interference fit in this
study, and the friction between them was estimated to
be the highest due to the compression forces they
would experience throughout the procedure. As can be
seen in the figure, the extrusion force required to
complete the process increases as friction increases.
The billet height increases the area of contact also
increases so resistance due to friction also increases
therefore the extrusion force increase. When die angle
increases the extrusion force also increases due
increase in strain which in turn increases the force
required for extrusion. The extrusion force also
decreases slightly with increase in core diameter this
mainly due the difference in flow stress of materials
since core materials (AZ31b) requires lesser to force to
extrude than the sleeve (Ti6Al4v).
Fig.9 Main Effect Plot for Extrusion Force
The regression equation obtained for Extrusion
force from RSM is given by Eq. (1)
ln (Extrusion force) = 5.141- 0.192 Core diameter
+ 0.1029 Billet height + 0.100 Ram speed
- 0.00496 Temp + 0.50 Cof - 0.00313 Die angle
The percentage contribution shown in Table 5 for each
parameter is obtained from the ANOVA table by
dividing the adjusted sum of squares value of the
corresponding term with the total sum of squares
value. From the Table 5, it was observed that billet
height, die angle and coefficient of friction are the most
significant parameters influencing the extrusion force.
It is verified that billet height is the most influencing
parameter with 10.71% contribution.
Table 6. Contribution of cutting parameters
Parameter Contribution (%)
Billet height 10.71
Core diameter 0.096
Die angle 7.4
Ram Speed 0.0508
Temp 1.527
Coe. of Friction 6.65
Figures 10 (a), (b), (c), (d), (e), (f), (g), (h), (i), (j), (k),
(l), (m) and (n) show 2D contour plot of extrusion force
for core diameter, billet height, die angle, ram speed,
Temperature, and coefficient of friction from DoE
software. From these contour plots we can infer that
minimum value of extrusion force occurs at high
values of core diameter, ram speed and temperature
with low values of billet height, die angle and
coefficient of friction.

Fig. 10(d) Contour Plot of Core dia and Cof on

Extrusion Force (kN)

Fig.10 (a) Contour Plot of Core dia and Billet height

on Extrusion Force (kN)

Fig. 10(e) Contour Plot of Core dia and die angle on

Extrusion Force (kN)

Fig. 10 (b) Contour Plot of Core dia and Ram speed

on Extrusion Force (kN)

Fig. 10(f) Contour Plot of Ram speed and Billet

height on Extrusion Force (kN)

Fig. 10(c) Contour Plot of Core dia and Temperature

on Extrusion Force (kN)
 Fig. 10(g) Contour Plot of temperature and Billet Fig. 10(j) Contour Plot of temperature and Ram
height on Extrusion Force (kN) speed on Extrusion Force (kN)

Fig. 10(h) Contour Plot of Cof and Billet height on Fig. 10(k) Contour Plot of Cof and Ram Speed on
Extrusion Force (kN) Extrusion Force (kN)

Fig. 10(i) Contour Plot of Die angle and Billet height Fig. 10(l) Contour Plot of Die angle and Ram Speed
on Extrusion Force (kN) on Extrusion Force (kN)

Fig. 10(m) Contour Plot of Cof and Temperature on
Extrusion Force (kN)
Fig. 10(n) Contour Plot of Die angle and
Temperature on Extrusion Force (kN) Simulation
Software
Fig. 10(o) Contour Plot of Die angle and Cof on
Extrusion Force (kN)
From the RSM response optimizer optimal extrusion
force value obtained with a goal of minimizing the
response value is 157 kN. Theminimum extrusion force
value and the corresponding optimum combination of
parameters obtained is highlighted as blue and red
respectively in fig. 12.
Fig.12 Optimization Plot
Then, simulations were run at these optimized
combination of extrusion parameters and noted the
extrusion force. This extrusion force was compared
with the predicted results and the comparison is
shown in Table 7 below. The error percentage is less
than 1 %.
Table 7. Comparison of Results
Extrusion force (kN)
Core diameter(mm)
Ram speed (mm/s)
Billet height (mm)
Die angle (0)
Temp (0C)
Cof
Abaqus
7 15 3 300 0.065 30 158
Minitab
7 15 3 300 0.065 30 157
4. CONCLUSIONS
A numerical model was developed to simulate
the bimetallic extrusion process involving Ti6Al4V
and AZ31B and predict extrusion force values using
ABAQUS/Explicit. The model was validated from
existing literature and was found to be in good
agreement with results in the existing literature.
Moreover, the developed model can be used for
analysis of the extrusion process. RSM was used in this
work for optimization and used to identify the optimal
extrusion parameters. The predicted extrusion force
value was compared with the simulation values.
Following are the main conclusions of this work;
• The developed numerical model can be used
effectively to predict the extrusion forces during
Bimetallic extrusion of Ti6Al4V and AZ31B alloys
• Using this FE model and RSM, it was found
that billet height is the most influencing parameter
followed by die angle and coefficient of friction.
• From the ANOVA results, minimum extrusion
force was obtained at low values of billet height, die Fernández D, Rodríguez-Prieto A, Camacho AM. 2021
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