Simulation of co-extrusion of Mg/Cu clad bi-metals using Fine Element Method

Abstract

In this paper finite element simulation of co-extrusion of Magnesium/Copper clad composite was carried out using DEFORM-2D software. In the simulation, a comparison between two models; a cup-shaped sleeve and a pipe-shaped sleeve was done to analyze flow behavior especially with regard to sleeve thickness (ts). The variation of load between the two set ups and the effect of core shortening for the pipe shaped sleeve
were analyzed. A cup-shaped sleeve resulted to a thinner sleeve diameter in comparison to a pipe-shaped sleeve and failure occurred for thin sleeves. In general a cup promotes concurrent flow of both core and sleeve but this is accompanied with material wastage. Concurrent flow of material can be promoted in a pipe sleeve set up by shortening the core. The results in the paper will contribute positively in the optimization of geometry in extrusion of bi-metals for applications in electrical and automobile industries.