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Materials Today: Proceedings 5 (2018) 11950–11961 www.materialstoday.com/proceedings

ICMMM - 2017

Forgeability Study of Al 6061 Alloy During Warm Forging of

Cylindrical Billets
P K Ajeet Babua*, M R Sarafa, K C Voraa,P Kuppanb
a
Automotive Research Association of India, Pune, 411028, India
b
VIT University, Vellore,632014, India

Abstract

Warm forging is a metal forming operation which is used to obtain near net shaped components and is considered as a trade-off
between cold and hot forging as optimum deformation load and temperature can be used for forging. In this present work, Al
6061-T6 alloy is selected and cylindrical billets were prepared for warm forging. Effect of homogenization on forgeability is also studied and
thus half of the samples are homogenized at 550°C for 8 hours. The initial raw material and the homogenized samples are warm
forged at two different temperatures i.e. 100°C and 150°C respectively. It is observed that all the samples are forgeable and no
cracks are observed and thus all the samples are further analysed for its various parameters. Longitudinal contraction (ln (ho/hf))
and diametrical expansion (ln (do/df)) are calculated and their relationship is found to be rectilinear. Radius of curvature and
maximum barrelling diameter is measured and their relationship proved that curvature of barrel follows the geometry of circular
arc. New geometrical shape factor (NGSF) is also calculated for the samples.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).

Keywords:Automotive structures, Warm Forging, Al6061

*
Corresponding author. Tel.: +91 8600881110;Fax.: +912135660830
E-mail address: ajeetbabu.fid@araiindia.com

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).
 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961 11951

NOMENCLATURE

h0 - Initial height (in mm)

d0 - Initial diameter /Initial contact diameter (in mm)
hf - Final height after forging (in mm)
db - Maximum barrelling diameter after forging (in mm)
dc - Final contact diameter after forging (in mm)
r - Barrelling ratio (db/hf) (in mm/mm)
Rc - Calculated radius of curvature (in mm)
Rm - Measured radius of curvature (in mm)
NGSF - New Geometrical Shape Factor (in mm)
εθ - diametrical expansion
εz - longitudinal Contraction

1. Introduction

One of the major challenges of today automotive industry is to meet the emission norms. Light weighting of the
automotive parts is a prominent solution and aluminium alloys are candidate material due to its properties such as
high wear resistance, equivalent specific rigidity and about twice the specific strength as compared to conventional
steel material.Time compression of aluminium forging is an important research area as this leads to higher
productivity. Hot forging is in use for decades but is considered as time and power consuming process as heating of
the material is required and waste generation due to excessive flash. There is a shift towards less energy consuming
and near net shape forging process such as cold and warm forging process. Cold forging produces net shape there
are limitations due to heavy load required for forging. Warm forging is an optimal choice as it has the advantages of
both hot and cold forging process such as high productivity, reduction in material waste and secondary operations
like trimming, strain hardening causes the better material properties of forged parts. The expected properties in
warm forged parts in heat treatable aluminium alloys can be obtained by providing the heat treatment cycle which
strengthens by precipitation hardening mechanism after the forging process [1].

Closed die forging process initiates with preparation of preform which is generally an upsetting process.Upsetting of
the cylindrical billets is the most widely employed forming process to study the flow of material, friction effect and
other parameters of forming processes. Friction between die/work piece interfaces plays an important role in the
deformation behaviour of the material and the study of friction in metal forming is carried out by many researches
[2-5]. In a frictionless condition deformation of the cylinder during upsetting is uniform and the surface remains
straight during forging however friction is observed between die and workpiece and strain is no longer uniform.

The barrelling profile of the samples assists in understanding the forgeability of the material. Kulkarni and Kalpakjin
noted the barrelling geometry is circular or elliptical and the initial length to diameter ratio influences the barrelling
geometry[6]. Schey reported a study on barrelling effect due to the dimensions of barrel, such as height to diameter
ratio or aspect ratio, instantaneous height to initial height or the ratio reduction ratio[7]. Banerjee and Narayanasamy
found the barrel radius as a function of height strain mathematically and confirmed it experimentally by relating the
bulge parameters after forging and the friction factor of the ring compression test during cold forging [8,9]. An
extensive amount of study has been done by Narayansamy on the cold forging and relations between parameters
like longitudinal hoop strain, diametrical hoop strain, and new geometrical shape factor are obtained based on
dimensions of the forged samples[10-16].

It is observed that Warm forging in steels is a successful application however for heat treatable aluminium alloys it
has received limited attention [2-6].This paper studies the effect of homogenization, forging temperature and the
aspect ratio on the forgeability of the warm forged samples by measuring the dimensions of the final geometry of the
forged samples.
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2. Experimental details

Aluminium 6061-T6 alloy is used to study the forgeability during warm upsetting. The chemical composition of
Al 6061 is shown in the table 1. Cylindrical samples of ф16 mm with two different aspect ratios i.e. 1.51 and 0.78
are obtained from the wrought alloy having length of 24mm and 12mm respectively, refer fig 1.Half of the samples
are homogenised at temperature 550°C for eight hours in a muffle furnace followed by air cooling and are hereafter
referred to as homogenised samples and the rest of the samples are referred to as non-homogenised samples. The
initial hardness of both homogenised and non-homogenised samples is measured by using Rockwell hardness F
scale. Because of speed, reproducibility and a relatively small indentation size, the F-scale Rockewell is used here,
refer table 2 for the values of hardness. The non- homogenised and homogenised samples are warm forged at two
different forging temperatures i.e. 100°C and 150°C and using graphite in mineral oil as die lubricant. The same
lubricant is also applied on top and bottom surface of the samples. The forging is carried out by using a 250 Ton
mechanical press, refer table 3 for the process parameters. Strain and the strain rate are kept constant during the
forging operation. Strain rate is calculated by using an accelerometer fixed to the top die and an eight channel data
acquisition system. The accelerometer fixed to the top of the die calculates the deceleration (g) values and strain rate
is then further calculated from the deceleration (g) values,refer table 4 for the strain rate value at two different
forging temperatures.

Table 1. Chemical composition (Wt. %) of Al 6061-T6 alloy

Element Si Fe Cu Mn Mg Cr Zn Ti
Standard 0.4- 0.8 0.7 max 0.15- 0.4 0.15 max 0.8- 1.2 0.04- 0.35 0.25 max 0.15 max
Observed 0.42 0.20 0.17 0.02 0.10 0.042 0.08 0.07

Table 2. Initial hardness of homogenised and non-homogenised samples

Condition Hardness (HRF)

Homogenized samples 50.5-51.6
Non-homogenized samples 73.9-76.8

a) b)

c) d)

Fig. 1. a) Photograph of undeformed billet samples of aspect ratio 0.78 b) Photograph of deformed billet
samples of aspect ratio 0.78 c) Photograph of undeformed billet sample of aspect ratio 1.51 d) Photograph
of deformed billet sample of aspect ratio 1.51.
 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961 11953

Table 3. Process parameters Levels

S.No. Parameters
1 Initial Condition Homogenized&Non- Homogenized
2 Forging Temperature 100°C&150°C
3 Aspect Ratio 0.78&1.51
4 Strain Rate 2.4925
5 Strain 50 %

Table 4: Strain rate at 100°C and 150°C for 250 Ton Mechanical Press

S.No. Sample forged at 100°C Sample forged at 150°C

1 2.49 2.49
2 2.47 2.52
Average 2.48 2.505

Crack analysis on the barreled surface is conducted by visual inspection .To carry outforgeability analysis, various
dimensions of the initial sample i.e. billet diameter and height and for the forged samples i.e. maximum barrelling
diameter, final contact diameter and final height is measured by using Verniercaliper by taking arithmetic mean of
four measurements at different positions, refer fig 2.
.

Fig.

3. Results and Discussion

3.1 Crack analysis
There is nocrack found in any sample of the aspect ratio of 0.78 and 1.51 forged at temperature 100°C and
150°C. At these temperatures both the homogenised and non-homogenised samples are found to be crack
free and thus considered as forgeable, refer fig 2 and 3
11954 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961

a.) b.)

c.) d.)

Fig. 2. a) Photograph of homogenised forged samples of aspect ratio 1.51at 100oCb) Photograph of non-
homogenised forged samples of aspect ratio 1.51 at 150oC c) Photograph of homogenised forged sample of
aspect ratio 1.51at 100oC d) Photograph of non-homogenised forged sample of aspect ratio 1.51at 150oC

e.) f.)

g.) h.)
Figure 3. a) Photograph of homogenised forged samples of aspect ratio 0.78at 100oC b) Photograph of non-
homogenised forged samples of aspect ratio 0.78at 150oC c) Photograph of homogenised forged sample of
aspect ratio 0.78at 100oC d) Photograph of non-homogenised forged sample of aspect ratio 0.78at 150oC.

3.2 Forgeability analysis

3.2.1 Longitudinal ContractionVs Diametrical expansion

The longitudinal contraction( ) anddiametrical expansion( ) are calculated for samples by using the formula

(1)

(2)

There has been found a linear relationship between longitudinal contraction and diametrical expansion as shown in
fig. 4 -11.
 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961 11955

0.5 Y= 0.4264X + 0.1205 R² = 0.9934 0.5 Y= 0.2424X + 0.1957 R² = 0.9968

0.48 0.48
Diametrical Expansion

Diametrical Expansion
0.46 0.46
0.44 0.44
0.42 0.42
0.4 0.4
0.38 0.38
0.36 0.36
0.685 0.69 0.695 0.7 0.705 0.685 0.69 0.695 0.7 0.705
Longitudinal Contraction Longitudinal Contraction

Fig. 4. For Initial Raw Material, The relationship between Fig. 5. For Initial Raw Material, The relationship between
Longitudinal Contraction and Diametrical expansion for samples Longitudinal Contraction and Diametrical expansion for samples
forged at 100°C with aspect ratio 1.51 forged at 100°C with aspect ratio 0.78

0.5 Y = 0.4677X + 0.148 R² = 0.9991 0.5 Y = 0.3991X + 0.1003 R² = 0.9986

0.48 0.48
Diametrical Expansion
Diametrical Expansion

0.46 0.46
0.44 0.44
0.42 0.42
0.4 0.4
0.38 0.38
0.36 0.36
0.685 0.69 0.695 0.7 0.705 0.685 0.69 0.695 0.7 0.705
Longitudinal Contraction Longitudinal Contraction

Fig. 6. For Initial Raw Material, The relationship between Fig. 7. For Initial Raw Material, The relationship between
Longitudinal Contraction and Diametrical expansion for samples Longitudinal Contraction and Diametrical expansion for samples
forged at 150°C with aspect ratio 1.51 forged at 150°C with aspect ratio 0.78

0.5 0.5
Diametrical Expansion

Y = 0.4255X + 0.1283 R² = 0.9978 Y= 0.3469X + 0.1249 R² = 0.9979

Diametrical Expansion

0.48 0.48
0.46 0.46
0.44 0.44
0.42 0.42
0.4 0.4
0.38 0.38
0.36 0.36
0.685 0.695 0.705 0.685 0.69 0.695 0.7 0.705
Longitudinal Contraction Longitudinal Contraction

Fig. 8. For Homogenized Material, The relationship between Fig. 9. For Homogenized Material, The relationship between
Longitudinal Contraction and Diametrical expansion for samples Longitudinal Contraction and Diametrical expansion for samples
forged at 100°C with aspect ratio 1.51 forged at 100°C with aspect ratio 0.78
11956 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961

0.5 Y = 0.4799X+ 0.1498 R² = 0.9998 0.5

Diametrical Expansion

Diamtetrical Expansion
0.48 Y = 0.3428X + 0.1555 R² = 0.9791
0.48
0.46 0.46
0.44 0.44
0.42 0.42
0.4 0.4
0.38 0.38
0.36 0.36
0.685 0.695 0.705 0.685 0.695 0.705
Longitudinal Contraction Longitudinal Contraction

Fig. 10. For Homogenized Material, The relationship between Fig. 11. For Homogenized Material, The relationship between
Longitudinal Contraction and Diametrical expansion for samples Longitudinal Contraction and Diametrical expansion for samples
forged at 150°C with aspect ratio 1.51 forged at 150°C with aspect ratio 0.78

3.2.2. Analysis of barrelling effect

The forgeability of sample is decided on the basis of the barrelling ratio which is define as ratio of barrel
diameter and final height of forged sample, mathematically expressed as

r= (3)

The geometrical curvature is found to be circular arc of radius R as shown in fig.12.

Fig. 12. The moulded cut section of forged sample

This is also proved analytically by Bannerjee and Narayanswamy[8,9]and the relation for calculated radius
of curvature is proved as

Rc = (4)
( )
 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961 11957

4.2 4.045 4.076

Aspect Ratio 0.78
3.8 3.933 3.964 Homogensied
Db/Hf( mm/mm)

3.4
NonHomogenised
3 Aspect Ratio 1.51
Homogenised
2.6
2.141 2.165 NonHomogenised
2.2
2.042 2.074
1.8
100 110 120 130 140 150
Temperature (oC)

Fig. 13. Barrelling behaviour in warm forging for aspect ratio 0.78 and 1.51 forged at temperature 100oC
and 150oC.
The effect of homogenisation on barrelling ratio is slightly higher than the non-homogenised samples.
For both aspect ratios 0.78 and 1.51 and deformation temperatures 100°C and 150°C calculated radius is
plotted as shown in fig. 13.
Barrelling ratio ‘r’ is higher (corresponding radius of curvature is lower in components ) for samples forged
at higher temperature 150°C as compared to 100°C. Similar results have been found for samples of lesser
aspect ratio (0.78) showing higher barrelling forged at same temperature as compared to higher aspect ratio
(1.51) as shown in fig 13 and fig.14 to 17.
Calculated Radius of curvature
Calculated Radius of curvature

6.32 6.32

5.82 5.82
( mm)
(mm)

5.32 100°C 5.32 100°C

4.82 150°C 4.82 150°C

4.32 4.32

3.82 3.82
0 2 4 6 0 2 4 6
No. of Readings No. of Readings

Fig. 14. For Initial Raw Material, The relationship calculated radius of Fig. 15. For Initial Raw Material, The relationship calculated radius of
curvature for samples of aspect ratio 1.51 and forged at 100°C & curvature for samples of aspect ratio 0.78 and forged at 100°C &
150°C 150°C
11958
Calculated Radius of curvature P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961

6.32

Calculated Radius of curvature

6.32

5.82 5.82
( mm)

5.32 100°C 5.32 100°C

( mm)
4.82 150°C 4.82 150°C
4.32
4.32
3.82
0 2 4 6 3.82
0 1 2 3 4 5
No. of Readings No. of Readings

Fig. 16. For Homogenized Material, The relationship calculated radius Fig. 17. For Homogenized Material, The relationship calculated radius
of curvature for samples of aspect ratio 1.51 and forged at 100°C & of curvature for samples of aspect ratio 0.78 and forged at 100°C &
150°C 150°C

It is also observed that the calculated radius of curvature is lower for samples forged at 150oC than 100oC. The
calculated radius for samples with 0.78 is in the range of 3.86 – 4.01 mm and 6.35 – 6.68 mm for samples with
aspect ratio of 1.51.
3.2.2 Measuredradius of curvature and New Geometrical Shape Factor

Measured radius is derived using eq. (3)

∆
Rm = (5)
∆

The samples are sectioned along its central axis and then moulded for measurement of ∆ . The measurement
valuesare taken using measuringmicroscope as shown in the figure below.

Fig. 18. The measurement of ∆ using midpoint of hf

The measured radius values are as follows :-

Temperature (0oC) Measured Radius of curvature (mm)

Aspect Ratio 0.78 Aspect Ratio 1.51
Homogenised Non-Homogenised Homogenised Non-Homogenised
100 4.88 4.90 7.50 7.61
150 4.80 4.83 7.28 7.34
This shows that the measured radius of curvature lies in the close proximity of calculated radius of curvature.There
is a linear relationship in measured radius of curvature and calculated radius of curvature.
 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961 11959

New Geometrical Shape Factor or NGSF is calculated usingequation(6) .

NGSF = × (6)
( )

Refer fig. 19 -26for relationship between calculated radius of curvature and NGSF

5
5 Y = 1.797X + 0.8173 R² = 0.9951
Y = 1.9048X + 0.5926 R² = 0.9864

Calculated radius ( mm)

4.95
Calculated radius ( mm)

4.95
4.9 4.9

4.85 4.85

4.8 4.8
4.75 4.75
4.7 4.7
2.15 2.2 2.25 2.15 2.2 2.25
NGSF NGSF

Fig. 19. For Initial Raw Material, The relationship between NGSF and Fig. 20. For Initial Raw Material, The relationship between NGSF and
Measured radius of curvature for samples forged at 100°C with aspect Measured radius of curvature for samples forged at 100°C with aspect
ratio 1.51 ratio 0.78

7.6 7.6
Y = 2.6636X - 0.0197 R² = 0.9787
Calculated radius ( mm)
Calculated radius ( mm)

Y = 1.9885X + 1.8325 R² = 0.9803 7.52

7.52
7.44 7.44
7.36 7.36
7.28 7.28
7.2 7.2
7.12 7.12
7.04 7.04
2.65 2.7 2.75 2.65 2.7 2.75
NGSF NGSF

Fig. 21. For Initial Raw Material, The relationship between NGSF and Fig. 22. For Initial Raw Material, The relationship between NGSF and
Measured radius of curvature for samples forged at 150°C with aspect Measured radius of curvature for samples forged at 150°C with aspect
ratio 1.51 ratio 0.78
11960 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961

5 5 Y = 3.3868X - 2.6016 R² = 0.9983

Y = 2.5772X - 0.7935 R² = 0.9765
4.95 4.95

Calculated radius ( mm)

Calculated radius ( mm)

4.9 4.9
4.85 4.85
4.8 4.8
4.75 4.75
4.7 4.7
2.15 2.2 2.25 2.15 2.2 2.25
NGSF NGSF

Fig. 23. For Homogenized Material, The relationship between NGSF Fig. 24. For Homogenized Material, The relationship between NGSF
and Measured radius of curvature for samples forged at 100°C with and Measured radius of curvature for samples forged at 100°C with
aspect ratio 1.51 aspect ratio 0.78

7.6 7.6
Y= 2.5018X + 0.6915 R² = 0.9811
Y= 2.8193X - 0.211 R² = 0.9993
Calculated radius ( mm)

7.52
Calculated radius ( mm)

7.52
7.44 7.44
7.36 7.36
7.28 7.28
7.2 7.2
7.12 7.12
7.04 7.04
2.65 2.7 2.75 2.65 2.7 2.75
NGSF NGSF

Fig. 25. For Homogenized Material, The relationship between NGSF Fig. 26. For Homogenized Material, The relationship between NGSF
and Measured radius of curvature for samples forged at 150°C with and Measured radius of curvature for samples forged at 150°C with
aspect ratio 1.51 aspect ratio 0.78

4. Conclusion

In the range of experiment conducted regarding temperature of 0°C and 25°C and aspect ratio of 0.78 and 1.51
results obtained from experiment draws the following conclusion.

1.) Homogenisation improves the material forgeability.

2.) The barrelling geometry is found to be circular in shape.
3.) The process of homogenising the raw material and taking billet of lower aspect ratio gives the higher
barrelling effect and increase the forgeability of the aluminium alloy 6061.
4.) Axial strain and hoop strain are linear in relationship and measured radius is very near to calculated radius
obtained analytically.
 P K Ajeet Babu et al. / Materials Today: Proceedings 5 (2018) 11950–11961 11961

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