Numerical Investigation of Round Profile Production: A Fem-Based Comparison between Friction Stir Extrusion and Conventional Extrusion

Friction Stir Extrusion, Direct Extrusion and Indirect Extrusion are all valid processes for the production of round extrudates. However, differences and similarities between them have yet to be analyzed by the scientific community, since with the same geometry, each technology instills specific properties to the extruded product. In this context, the present work presents an in-depth analysis via QForm UK Finite Element Method software of the effect that each process has on a AA6061 extruded wire. Various combinations of rotational speed (200, 400, 600 rpm), feed rate (1, 2, 3, 4 mm/s) and pre-heating temperature (450, 500°C) were analyzed to assess differences and similarities between the different processes.