BY-Andrzej Rosochowski &Wojciech Presz & Lech Olejnik & Maria

Richert
(International Journal of Advance Manufacture Technology(2007))

Presented by-
NITIN DWIVEDI(20063008)
RAHUL PEDAPUDI(20063062)

AIM
Backward extrusion is carried out for two types of
material, CG and UFG aluminium. Their behavior and
mechanical properties are compared to decide which
is best for the micro parts.
The author has manufactured a cup of following
dimensions to study the properties:
external dia : 1.80mm
internal dia : 1.24mm
height : 1.30mm
depth : 1.05mm


What is Fine Micro-Extrusion?
Micro forming is understood to be the production
of parts or structures with at least two dimensions
in the sub-millimeter range. Micro forming of
normal, coarse grain (CG) metals leads to scale
problems which originate from the fact that the
grain size becomes comparable to the part size. A
possible way of dealing with these problems is
replacing CG metals with ultra-fine grained (UFG)
metals. UFG metals can be produced in bulk by
severe plastic deformation (SPD).
INTRODUCTION
Ultra-fine grained (UFG) metals produced by
either powder metallurgy or severe plastic
deformation (SPD). The powder metallurgy
route, which involves Nano powders, enables
obtaining grains smaller than 0.1 m. However,
the cost, residual porosity and health issues are
the known concerns for this route. SPD, which is
based on inducing a very large plastic
deformation without basically changing the
shape of the billet, can reduce the original grain
size of the material to approximately 0.11 m.
Obtaining UFG Aluminium
1)UFG Metals
Very high yield and ultimate strength.
Reasonable ductility.
High impact strength at low temperatures.
Super plastic at elevated temperatures.
Existing applications of UFG metals are in
medical transplants, structural parts for
automotive and aerospace industries,
defense systems and sports equipments.
Nanostructuring of Aluminium by SPD

There are numerous SPD
processes, which are
used on a laboratory
scale. There are no
industrially accepted SPD
processes as yet. The
most popular SPD
process is equal channel
angular pressing (ECAP).
It is based on forcing a
metal billet through an L-
shaped channel of
constant profile (usually
square or round).
a) The initial shape of the billet
b) Partially extruded billet
c) Billet after leaving the die
Mechanical properties of CG and UFG aluminium
1070
The material used was commercially pure aluminium 1070. It was
supplied in the form of a hot extruded round bar, 38 mm in diameter.
Metallurgical testing showed that the initial average grain size was
approximately 500 m.
After three consecutive passes through a 3D-ECAP die, the amount of
plastic strain generated in the material reached 10.35. Such a large
strain led to grain refinement with the average grain size of 0.2 m
Table 1:Mechanical properties of CG and UFG aluminium 1070
Material
grade
Yield
strength
Re (MPa)
Ultimate
Tensile
strength
Rm
(MPa)
Elongation
To fracture
A5 (%)
Area
reduction
at fracture
Z (%)
CG Al
56 73 39 97
UFG Al
173 188 16 72
Step 1:Producing plates for blanking

Step 2:Blanking of Billets
1. Plate
2. Die
3. Blank holder
4. Punch
5. Blank

Step 3 :Closed die compression and Backward extrusion of
Micro-cup
1. Blank
2. Die
3. Cylindrical support
4. Pressing punch
5. Punch guide
6. Support plate
7. Base plate


Punches used in various steps



























Tip of punch used for backward extrusion


Blanking force for CG and UFG aluminium
a, b Extruded aluminium cups a CG b UFG
Parameters of the multi-stage forming process used for
manufacturing of micro-cups
Forming process Punch velocity
(mm/min)
Tool diameter(mm)
Punch Die
Blanking with blank
holder
1 1.60 1.67
Close die compression 0.1 1.60 1.80
Backward extrusion 0.1 1.24 1.80
Characteristics of Extruded Cup













UFG Aluminium CG aluminium

HARDNESS

CONCLUSION

UFG metals seems to be a better option for micro
forming.

More uniform structure, better shape representation and
enhanced properties of micro parts.

More uniform flow of the material and suggested a better
shape capability.