Analysis and porthole die design for a multi-hole extrusion process of a hollow, thin-walled aluminum profile

2014 ◽  
Vol 74 (1-4) ◽  
pp. 383-392 ◽  
Author(s):  
Liang Chen ◽  
Guoqun Zhao ◽  
Junquan Yu ◽  
Wendong Zhang ◽  
Tao Wu
Keyword(s):  
Extrusion Process ◽  
Die Design ◽  
Porthole Die ◽  
Aluminum Profile ◽  
Thin Walled

FVM Simulation of Porthole Die Extrusion Process for a Large Caliber Aluminum Tube Profile

2015 ◽  
Vol 778 ◽  
pp. 116-119
Author(s):  
Rui Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Finite Volume Method ◽  
Finite Volume ◽  
Extrusion Process ◽  
Aluminum Tube ◽  
Porthole Die ◽  
Aluminum Profile ◽  
Volume Method ◽  
Aluminum Profile Extrusion

Aiming at the aluminum profile extrusion process of a large caliber aluminum tube with porthole die, this paper established the simulation models by using finite element method and finite volume method, respectively. The extrusion process was simulated by using the above two models. The advantages and disadvantages and the applicability of the two simulation methods in simulating large aluminum profile extrusion processes were compared. It is concluded that finite volume method is more suitable than finite element method for simulating aluminum profile extrusion processes with a severe deformation. In addition, the distributions of stress and strain and the material flow patterns in the large caliber aluminum tube extrusion process with porthole die were given in detail. The results can provide useful theoretical guidelines for the process and die design as well as process parameter optimal selection for large aluminum profile extrusion processes with porthole die.

Die Optimal Design for a Large Diameter Thin-Walled Aluminum Profile Extrusion by ALE Algorithm

2011 ◽  
Vol 306-307 ◽  
pp. 459-462
Author(s):  
Peng Liu ◽  
Shui Sheng Xie ◽  
Lei Cheng
Keyword(s):  
Optimal Design ◽  
Flow Velocity ◽  
Material Flow ◽  
Large Diameter ◽  
Extrusion Process ◽  
Arbitrary Lagrangian Eulerian ◽  
Initial Design ◽  
Aluminum Profile ◽  
Thin Walled ◽  
Aluminum Profile Extrusion

Extrusion process of a large diameter thin-walled aluminum profile was simulated by Arbitrary Lagrangian Eulerian (ALE) algorithm based on HyperXtrude software. The results show that the material flow velocity in the bearing exit of the initial design die is non-uniform. Three times modifications were performed and simulated. The optimal design with more uniform flow velocity in the bearing exit was obtained.

Numerical Simulation for Extrusion Process of Thin-Wall Aluminum Profile with Large Flakiness Ratio and Optimization Die Design

2015 ◽  
Vol 778 ◽  
pp. 55-58
Author(s):  
Xiao Fei Ma
Keyword(s):  
Numerical Simulation ◽  
Design Optimization ◽  
Optimization Method ◽  
Extrusion Process ◽  
Die Design ◽  
Velocity Analysis ◽  
Thin Wall ◽  
Exit Velocity ◽  
Aluminum Profile

The numerical simulation of a thin-wall aluminum profile was introduced. Then the velocity and temperature of the extrusion process were given. A die design optimization method was proposed by the velocity analysis. After optimization, a profile with uniform exit velocity was gain. Finally, a method for this profile die design was summarized.

scholarly journals Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1517 ◽  
Author(s):  
Zhiwen Liu ◽  
Luoxing Li ◽  
Shikang Li ◽  
Jie Yi ◽  
Guan Wang
Keyword(s):  
Metal Flow ◽  
Extrusion Process ◽  
Width Ratio ◽  
Small Cavity ◽  
Porthole Die ◽  
Aluminum Profile ◽  
Die Structure ◽  
Length Width ◽  
Die Extrusion ◽  
High Length

The design of a porthole die is one of the key technologies for producing aluminum profiles. For an aluminum profile with high length–width ratio and small cavity, it is difficult to control the metal flow through porthole die with the same velocity to ensure the die’s strength. In the present study, the porthole die extrusion process of aluminum profile with small cavity was simulated using HyperXtrude 13.0 software based on ALE formulation. The simulation results show for the traditional design scheme, the metal flow velocity in porthole die at every stage was severely not uniform. The standard deviation of the velocity (SDV) at the die exit was 19.63 mm/s. The maximum displacement in the small mandrel was 0.0925 mm. Then, aiming at achieving a uniform flow velocity and enough die strength, three kinds of die structure modifications for the porthole die were proposed. After optimization, desired optimization results with SDV of 0.448 mm/s at the die exit and small mandrel deflection were obtained. Moreover, the temperature uniformity on the cross-section of die exit, welding pressure, and die strength were improved greatly. Finally, the optimal porthole die was verified by the real extrusion experiment. A design method for porthole die for aluminum with a high length–width ratio and small cavity was proposed, including sunken port bridges to rearrange the welding chamber in upper die, increasing the entrance angle of portholes, introducing the baffle plate, and adjusting the bearing length.

scholarly journals Analysis and optimization of cooling channels performances for industrial extrusion dies

2021 ◽  
Author(s):  
Riccardo Pelacci ◽  
Marco Negozio ◽  
Barbara Reggiani ◽  
Lorenzo Donati ◽  
Luca Tomesani
Keyword(s):  
Liquid Nitrogen ◽  
Numerical Models ◽  
Extrusion Process ◽  
Die Design ◽  
Design Stage ◽  
Fe Model ◽  
Cooling Efficiency ◽  
Channel Design ◽  
Liquid Nitrogen Cooling ◽  
Experimental Trials

Liquid nitrogen cooling is widely used in the extrusion industrial practice in order to increase the production rate, to reduce the die temperature and to avoid defects on the profile exit surfaces resulting from an excessive heating. However, the efficiency of the cooling is deeply affected by position and design of the liquid nitrogen channel so that numerical modelling is gaining an increasing industrial interest in relation to the possibility offered to optimize the channel design without expensive and time-consuming experimental trials. In this work, a numerical FE model developed within COMSOL Multiphysics® is proposed and validated against experimental trials performed in industrial environment. The model combines the 3D simulation of the extrusion process with a 1D model of the cooling channel thus allowing the testing of a number of different solutions at the die design stage. The global aim of this work is the assessment of the liquid nitrogen cooling efficiency in the extrusion of an industrial aluminum profile and the proof of the potentials offered by numerical models to get an optimized channel design in terms of cooling efficiency, die thermal balancing and reduction of liquid nitrogen consumption.

Analysis of Extrusion Welding Conditions for AlMg Alloys with High Mg Content

2016 ◽  
Vol 682 ◽  
pp. 401-407 ◽  
Author(s):  
Alicja Wojtyna ◽  
Dariusz Leśniak ◽  
Artur Rękas ◽  
Tomasz Latos ◽  
Krzysztof Zaborowski ◽  
...  
Keyword(s):  
Aluminium Alloys ◽  
Original Method ◽  
Die Design ◽  
High Quality ◽  
Weldability Tests ◽  
Welding Stress ◽  
Porthole Die ◽  
Extrusion Welding ◽  
Wide Range ◽  
Mg Content

In the work, an original method and a special modified device is presented enabling to determine welding conditions of hard deformable aluminium alloys. The main advantage of the proposed method is that it simulates conditions occurring in the welding chamber of the porthole dies. The weldability tests were performed for 5754 (3,5% Mg) and 5019 (5,5% Mg) alloys, in a wide range of temperatures and pressures. The microstructure and joints strength were examined. The welding conditions of AlMg alloys that allowed obtaining high-quality joints were determined. The obtained welding stress values will be the basis for extrusion porthole die design.

Constitutive Laws for the Deformation Estimation of Extrusion Die in the Creep-Fatigue Regime

2011 ◽  
Vol 491 ◽  
pp. 233-240 ◽  
Author(s):  
Barbara Reggiani ◽  
Lorenzo Donati ◽  
Luca Tomesani
Keyword(s):  
Experimental Data ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Primary Phase ◽  
Time Curve ◽  
Hardening Law ◽  
Porthole Die ◽  
Creep Fatigue ◽  
Temperature Levels ◽  
Testing Condition

Tools are exposed to severe working conditions during the hot extrusion process. In particular, dies and mandrels can be subjected to an excessive amount of deformation as a result of the developed high cyclic loads and temperatures. In this scenario, a physical experiment reproducing the thermo-mechanical conditions of a mandrel in a porthole die was performed with the Gleeble machine on the AISI H11 tool steel with the aim to investigate the mechanisms that influence the die deformation. The design of experiment consisted of 4 levels of temperature, 3 levels of stress and 3 types of load, i.e. pure creep, pure fatigue and creep-fatigue. In all the testing conditions, a comparable pattern of the mandrel displacement-time curve was found reproducing the 3 stages of softening typical of the strain evolution in a standard creep test but with a marked primary phase. Thus, with the aim to identify an easy-applicable equation to estimate the die deformation, the time hardening creep law was chosen. Coefficients of the time-hardening law were optimized, for each testing condition, on the basis of experimental data starting from values for similar alloys taken from the literature. Results in terms of mandrel displacement were then compared to experimental data for the creep-fatigue condition at different stress and temperature levels. The values found were validated against additional experimental data performed with different specimen geometries. A good average agreement was found between experimental and numerical results. The developed procedure was then applied to an industrial die.

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