EXPERIMENTAL AND NUMERICAL ANALYSIS OF THE EFFECTS OF EXTRUSION REDUCTION RATIO AND LOAD ON AL 6063 FORMING PARAMETERS

Temitayo Mufutau Azeez; Phuluwa Simon  Humbulani; Zviemurwi Johnny  Chihambakwe; Mariam Iyabo  Adeoba

doi:10.4314/njt.2026.5425

Authors

Temitayo Mufutau Azeez Department of Industrial Engineering and Management, University of South Africa, Florida Campus, South Africa.
Phuluwa Simon Humbulani Department of Industrial Engineering and Management, University of South Africa, Florida Campus, South Africa
Zviemurwi Johnny Chihambakwe Department of Industrial Engineering and Management, University of South Africa, Florida Campus, South Africa
Mariam Iyabo Adeoba Department of Mechanical, Bioresources and Biomedical Engineering, University of South Africa, Florida Campus, South Africa.

DOI:

https://doi.org/10.4314/njt.2026.5425

Keywords:

Extrusion parameter optimization, Extrusion ratio, Load, Model equation, Flow stress simulation

Abstract

The applied load and extrusion reduction ratio effects on the Al 6063 alloy mechanical performance and microstructure were researched through a combined numerical and experimental approach. Extrusion trials were conducted at three loads and extrusion reduction ratios (20, 25, 30 MN) and (25 %, 50 %, 75 %) respectively. Tensile strength and Vickers hardness were measured, and quadratic second‑order polynomial model was fitted for these responses’ prediction. ANOVA confirmed that both parameters and their interaction are statistically significant (p < 0.05), and confirmatory experiments revealed model errors of less than 5 %. The peak hardness and tensile strength values of 88.25 HV and 280.15 MPa were obtained at 25 MN load and 12.5 % extrusion reduction ratio, while response‑surface optimization revealed 48.32 % ratio and 27.44 MN load as the optimum for balanced strength and hardness. Extrusion process numerical simulations through QForm software were performed at the same extrusion reduction ratios and loads for material deformation and flow‑stress evolution assessment. The simulations showed that flow stress increases with decreasing extrusion ratio, attaining its peak at 25 % ratio, and that higher loads reduce flow stress, enhancing fatigue resistance. The simulation time‑displacement curves showed that a 25 % ratio requires the longest deformation time (≈108 min) compared with 12–24 min for 50–75 % ratios. Microstructural analysis affirmed grain refinement at 25 % and 50 % ratios, with the most uniform grain distribution. Both the numerical and experimental data simulations has shown that load and extrusion ratio optimization not only maximizes tensile strength and hardness but also influence flow stress and grain structure, enabling a detail framework for high‑performance Al 6063 components production.

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