Numerical simulation and parametric optimization of hot deformation behavior of copper-based composite material

In present study, stir casting was used in this study to fabricate copper-based composite with varying compositions of SiC, 1 wt% graphite, and 2 wt% Cr at a speed of 500 RPM, stirring at a temperature of 1200 °C, and stirring for 30 min. The DEFORM 3D was employed for numerical simulation of hot extrusion of Cu–SiC–Cr–Gr composite with overall enhanced properties at varying extrusion ratio (2, 3, 4 and 5), speed of ram (1, 2, 3 and 4 mm/s) and temperature of billet (950, 900, 850 and 800 °C). The value of load and damage of extrusion were measured and analyzed as single response characteristics through Taguchi’s signal to noise (S/N) ratio and Taguchi based grey relational analysis (TBGRA) as multi-response characteristics. The findings showed that both damage and extrusion load was increased with increasing extrusion ratio of cosine die for Cu–6SiC–2Cr–1Gr composite which was finally extruded with optimum combination of parameter. The result after extrusion shows that porosity percentage was decreased from 2.71 to 1.57% when compared to sample before extrusion. Compression strength and hardness of Cu–6SiC–2Cr–1Gr were improved by 21.4% and 17.4% respectively following extrusion although electrical conductivity showed slight decrement.