Optimum Process Parameters for Enhanced Uniform Hardness Distribution and Barreling Behavior in Upsetting

Abstract

The present work focuses on the application of ‘Taguchi’ optimization technique for the upsetting of AA2014 cylindrical billets. Different height (h) to the diameter (d) ratios, different lubricants, and billets aged to different times were considered as process parameters. The experimental results proved that the hardness is not uniform throughout the entire billet and will vary with the lubricant employed at the die/billet interface, height to the diameter ratios and ageing condition. The process parameters were optimized to get uniform distribution of hardness in the billet, to reduce the deformation load and barreling effect. Using ANNOVA analysis, the percentage contribution of each factor was determined. To test the accuracy of the predicted results, confirmation experimental runs were conducted and the results were validated.