The surface roughness of extrusion tools plays a crucial role in determining the efficiency and quality of cold work extrusion processes. This study investigates the effects of tool surface roughness on various dynamics of cold work extrusion, focusing on parameters such as material flow, surface finish of the extruded product, and tool wear. Through a series of controlled experiments, different surface roughness levels were applied to extrusion tools, and their impact on extrusion performance was analyzed. Key metrics, including extrusion force, product dimensional accuracy, and surface finish, were measured and compared across varying roughness conditions. The study also examines the relationship between surface roughness and tool wear rates, providing insights into the long-term implications of surface texture on tool life and maintenance. The results reveal that tool surface roughness significantly influences extrusion dynamics. Smoother tool surfaces generally resulted in improved material flow, better surface quality of the extrudate, and reduced extrusion forces. Conversely, increased surface roughness led to higher friction, greater force requirements, and decreased surface quality. Additionally, tools with rougher surfaces exhibited accelerated wear, affecting their longevity and performance. This research provides valuable insights into optimizing tool surface finish to enhance the efficiency and quality of cold work extrusion processes. The findings highlight the importance of tool surface preparation and maintenance in achieving desired extrudate properties and extending tool life.

Tool Surface Roughness, Cold Work Extrusion, Extrusion Dynamics

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