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Numerical modeling and experimental investigation of brass wire forming by friction stir back extrusion

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Abstract

Friction stir back extrusion (FSBE) is used to produce brass wires, and then numerical modeling is developed to model the process by the coupled Eulerian-Lagrangian (CEL) technique and verified by experiments. Next, the effects of FSBE parameters, including tool rotational and plunging speed, on the strain and temperature distributions, microstructure, and material flow patterns are studied. The results show that the highest temperature and strain occur near the tool/workpiece interface but at a further distance from the tool axis. Additionally, in the cross section of an FSBE wire, the microstructure is more refined in the sample’s periphery. A higher rotational speed or a lower plunging speed results in a coarser microstructure. The material flow pattern is a conical helix and does not change meaningfully by the process parameters. The points at the further distance from the tool axis, along with an upward movement, experience an inward spiral motion which is amplified by higher rotational speed. However, the materials near the tool axis almost take an upward movement and endure a significantly lower strain.

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Data availability

All of the required experimental data for reproduction of these findings are explained with details in the section “Experimental procedure.”

The general data for the reproduction of the proposed simulation model are described in the section “Model description”; however, some minor details cannot be shared at this time as the data also form part of an ongoing study.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering, Imam Khomeini International University, Qazvin, Iran

    Parviz Asadi

  2. Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran

    Mostafa Akbari

Authors
  1. Parviz Asadi
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  2. Mostafa Akbari
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All the authors have participated in the conception, design, analysis, and interpretation of the data as well as the writing, drafting, and revising of the article.

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Correspondence to Mostafa Akbari.

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Ethics approval

Since the study is performed on the metallic samples, there is no need for ethical approval; however, all the tests are done in Imam Khomeini International University, in the metal forming, material processing, and SEM Labs under the control of trained experts. Additionally, the paper’s primary data is not published elsewhere.

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All the authors declare that they have agreed to authorship, have read and approved the manuscript, and have given consent for submission and subsequent publication.

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The authors declare no competing interests.

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Asadi, P., Akbari, M. Numerical modeling and experimental investigation of brass wire forming by friction stir back extrusion. Int J Adv Manuf Technol 116, 3231–3245 (2021). https://doi.org/10.1007/s00170-021-07729-5

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  • DOI: https://doi.org/10.1007/s00170-021-07729-5

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