Optimization of Deformation Behaviors during Continuous Forming Extrusion of C18150 Copper Alloy through Response Surface Methodology

Continuous extrusion (CE) is a method of creating endless profiles of high-quality products of dimensional accurateness, high productivity, and excellent material properties. The main objective of this study is to investigate the influence of CE input process parameters on optimal overall extrusion load requirement and effective stress induced. The input parameters considered were extrusion driving wheel speed, feed metal temperature, tool temperature, and factor of friction proceeding. Numerical simulations of a copper alloy (C18150) were carried out using DEFORM-3D to investigate the impact of the input variables on total load and effective stresses. A mathematical model based on response surface methodology (RSM) was developed for optimized results. The optimized parameters in terms of wheel extrusion velocities, feedstock temperatures, tool temperatures, and friction factors expressed. The ANOVA test was performed to assess the suitability and appropriateness of the model. Using RSM, the optimal load value of 408.167 kN and effective stress of 1241.0 MPa were achieved within the composite preference of 1.0. A load of 408.167 kN had been obtained if the velocity of the wheel, temperatures of feedstock, tool temperatures, and factors of friction are 4 rpm, 500°C, 400°C, and 0.85, respectively. The minimum effective stress of 1241.0 MPa is induced in the feedstock due to the CE process if the velocity of the wheel, temperature of the feedstock, die temperature, and frictional factor were 4 rpm, 500°C, 400°C, and 0.95, respectively.