Multi-Objective Optimization of Multi-Channel Spiral Twist Extrusion Process Using a Response Surface Approach and Finite Element Analysis




Abstract: Multi-channel spiral twist extrusion (MCSTE) is a novel design [US Provisional patent application 62/492,456] capable of providing an effective, cost-saving SPD process was evaluated and validated. In this study, response surface method and finite element analysis were employed to model the MCSTE deformation behavior at room temperature. An optimal design was used to plan the experiments on Al alloys. The number of passes, route type and punch speed were selected as input factors, while hardness and tensile properties were modeled as the response. The analysis of variance was applied to investigate the influence of the processing factors and their interactions. The effective strain and stresses as a function of the number of passes were investigated. Hardness contour maps perpendicular to MCSTE direction were plotted. Processing via MCSTE angle of 40o produced effective strain values equivalent to those produced by conventional twist extrusion dies with 60o twist angles.

Authors: D.M. Fouad, A. Moataz, W.H. El-Garaihy, and H.G. Salem

Keywords: Severe Plastic Deformation, Multi-Channel Spiral Twist Extrusion, Finite Element Modelling (FEM), Response Surface Approach (RSA)

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8 pages


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