An Improved Process Design for the Hot Backward Extrusion of Ti-6Al-4V Tubes Using a Finite Element Method and Continuum Instability Criterion

Abstract The hot backward extrusion process of Ti-6Al-4V tubes was designed by finite element (FE) simulation and experimental validations. In the hot backward extrusion of Ti-6Al-4V alloy, the main problems to emerge were surface cracks and sticking between the punch and the workpiece. The punch designs and back draft angles were investigated with a common hot backward extrusion condition. Then, based on a relatively good die design, the optimum process conditions were suggested. The design criteria were to achieve uniform distributions of strain and temperature and to produce a defect-free final product. As a model for predicting the forming defects, the continuum instability criterion developed by Ziegler was coupled to the internal variables generated from FEM simulation. Experimental observations were carried out on the extruded Ti-6Al-4V tubes to validate the model for predicting the forming defects. The die-chilling and friction greatly influenced the deformation mode of the tube and the formation of surface cracks. The formation of defects in the extruded tube was attributed to the non-uniform distribution of strain, strain rate, and temperature in the extruded tubes at the given experiment conditions.