Selection of Optimal Tool Geometry for the Production of Brass Wires Using the FSBE Method

This research studied different tools with different cone angles to produce brass wires using the friction stir back extrusion (FSBE) method. The cone angle of the tool is one of the most influential parameters in the production of brass wires. First, to determine the appropriate cone angle, the FSBE process is modeled using the Coupled Eulerian-Lagrangian (CEL) method. The simulation results showed that increasing the cone angle increases the heat generated and reduces the force on the tool. Also, to be more precise, the mechanism of heat production during the process was numerically modeled to verify the simulation results. The cross-sectional images of the wires produced showed that only tools with a cone angle of 35 ° could produce flawless wires. The microstructural results showed that the grain size in the center of the wire was 20.24 microns, which is larger than the size in the wire periphery, which was 16.88 microns. This microstructural deviation is mainly affected by the strain and the temperature.