Experimental and Numerical Analysis of the Extrusion Process in the Forming of Metal Composite Metal Billets

Composite materials are of great interest due to their exceptional strength, hardness-to-density ratio, high corrosion resistance, and low weight. One of the suitable methods for making composite pipes is using the extrusion process. Extrusion is a plastic deformation process that due to the compressive state of stress in extrusion, materials with low plasticity can be formed by this method. This article deals with the experimental-numerical investigation of extrusion, from various methods of forming process. Extrusion is done on a composite tube using aluminum and magnesium alloys. Aluminum is used due to its strength compared to high weight, excellent malleability, and magnesium due to the lightest structural metal, the lowest density among structural materials, machining, welding and casting capabilities, as well as high specific strength. The mentioned process was tested at different extrusion ratio, temperature and speed, and the effect of different process parameters on the properties of the extruded product was investigated. Then the process was simulated in the software and the experimental results obtained from the laboratory work and the numerical results obtained from the simulation were compared and validated with each other and the error percentage between the graphs of the experimental and numerical results was examined.