Numerical Analysis of Process Parameters and Tool Geometry in Friction Stir Back Extrusion of Pure Aluminum

Friction Stir Back Extrusion (FSBE) is an innovative process that offers efficient aluminum waste recycling and wire production. This process boasts economic and environmental advantages, as it requires minimal energy compared to traditional recycling casting methods. The objective of this study is to analyze the impact of process parameters using a Finite Element Method (FEM) model based on thermo-mechanical 3D Lagrangian. The study focuses on an AA1080 aluminum alloy and employs different geometric tools, including hole extrusion diameters of 4 mm and 8 mm, as well as a shoulder with two distinct angles of 10° and 15°. Furthermore, variations in several process parameters, such as a constant axial feed rate of 0.5 and 1 mm/min and a constant rotational speed of the die set at 100, 300, and 500 rpm, are considered. The simulation plan encompasses a total of 24 combinations of these parameters to identify the optimal conditions for chips extrusion. Subsequently, the obtained results were analyzed using Design of Experiments (DoE) analysis to assess the influence of each parameter on peak force, torque, and temperature during the process.