Mathematical model of small-diameter wires extrusion from biocompatible MgCa08 (Mg - 0.8% Ca) magnesium alloy was developed in the current paper in order to determine window of allowable technological parameters. Compression and tensile tests were carried out within temperature range 250-400°C and with different strain rates to determine the fracture conditions for the studied alloy. Finite element (FE) analysis was used to predict the billet temperature evolution and material damage during processing. The extrusion model takes into account two independent fracture mechanisms: a) surface cracking due to exceeding of the incipient melting temperature and b) utilization of material formability. FE simulations with different initial billet temperatures and pressing speeds were performed in order to determine the extrusion limit diagram (ELD) for MgCa08 magnesium alloy. The developed ELD was used to select the parameters for the direct extrusion of wires with diameter of 1 mm. Then, the extrusion of twelve wires was conducted at 400°C with pressing speed 0.25 mm/s. It was reported that the obtained wires were free from defects, which confirmed the good agreement between numerical and experimental results.
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