Spray footprint effect on the induced distortion by the cooling process in the aluminum extrusion process

2013 ◽  
Vol 57 (1-2) ◽  
pp. 14-23 ◽  
Author(s):  
Saeed Bikass ◽  
Bjørn Andersson ◽  
Artem Pilipenko ◽  
Hans Petter Langtangen
Keyword(s):  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Cooling Process ◽  
Footprint Effect

Modeling of Aluminum Extrusion Process Using Non-Orthogonal Block Structured Grids Based FVM

2011 ◽  
Vol 189-193 ◽  
pp. 1749-1752
Author(s):  
Rui Wang ◽  
Hong Zhong Li
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Special Treatment ◽  
Aluminum Extrusion ◽  
Rigid Plastic ◽  
Structured Grids ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Die Extrusion

The mathematic model of 3D aluminum extrusion processes using finite volume method (FVM) was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Non-orthogonal structured grids were used to match complex geometric boundaries and local refinement of grids was also realized. The collocated arrangement is used to discretize the governing equations on non-orthogonal grids directly, pressure oscillations bring by this arrangement and error caused by grid’s non-orthogonality is eliminated by special treatment. A pocket die extrusion process was simulated using the program developed in this paper. The simulation results were also compared with that simulated by FEM software Deform in the same process, material and die conditions. The feasibility and efficiency of the mathematic model built in this paper was demonstrated by the simulation results and the comparison.

Modeling and Simulation of Microstructure Evolution in Extruded Aluminum Profiles

2009 ◽  
Vol 424 ◽  
pp. 43-50
Author(s):  
Farhad Parvizian ◽  
T. Kayser ◽  
Bob Svendsen
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloys ◽  
Modeling And Simulation ◽  
Microstructure Evolution ◽  
Internal State ◽  
Extrusion Process ◽  
State Variables ◽  
Cooling Process ◽  
Microstructure Parameters ◽  
Simulation Results

The purpose of this work is to predict the microstructure evolution of aluminum alloys during hot metal forming processes using the Finite Element Method (FEM). Here, the focus will be on the extrusion process of aluminum alloys. Several micromechanical mechanisms such as diffusion, recovery, recrystallization and grain growth are involved in various subsequent stages of the extrusion and the cooling process afterward. The evolution of microstructure parameters is motivated by plastic deformation and temperature. A number of thermomechanical aspects such as plastic deformation, heat transfer between the material and the container, heat generated by friction, and cooling process after the extrusion are involved in the extrusion process and result in changes in temperature and microstructure parameters subsequently. Therefore a thermomechanically coupled modeling and simulation which includes all of these aspects is required for an accurate prediction of the microstructure evolution. A brief explanation of the isotropic thermoelastic viscoplastic material model including some of the simulation results of this model, which is implemented as a user material (UMAT) in the FEM software ABAQUS, will be given. The microstructure variables are thereby modeled as internal state variables. The simulation results are finally compared with some experimental results.

Study of Flow Balance and Temperature Evolution over Multiple Aluminum Extrusion Press Cycles with HyperXtrude 9.0

2009 ◽  
Vol 424 ◽  
pp. 257-264 ◽  
Author(s):  
Amin Farjad Bastani ◽  
Trond Aukrust ◽  
Inge Skauvik
Keyword(s):  
Finite Element ◽  
Finite Elements ◽  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Billet Temperature ◽  
Exit Velocity ◽  
Extrusion Press ◽  
Flow Balance ◽  
Exit Temperature ◽  
Ram Speed

In this research, transient finite element simulations of the aluminum extrusion process have been performed in order to study how process parameters influence flow balance and exit temperature. This has been achieved by investigating the influence of billet taper, front billet temperature and ram speed on the run-out velocity and temperature of two separate outlets. Analysis of variance (ANOVA) has been employed to study the effect of each parameter on the velocity and temperature variation of the extruded section. Results show that increasing each of these three parameters results in an undesired increase in exit velocity and temperature. The front billet temperature is found to be the most significant factor affecting the variation. The finite elements software used was Altair HyperXtrude 9.0.

Aluminum Rod Extrusion and Material Modeling

2008 ◽  
Vol 367 ◽  
pp. 71-78
Author(s):  
P.T. Moe ◽  
Yawar Abbas Khan ◽  
Henry Sigvart Valberg ◽  
Sigurd Støren
Keyword(s):  
Temperature Measurement ◽  
Constitutive Relations ◽  
Simulated Data ◽  
Thermal Conditions ◽  
Extrusion Process ◽  
Material Modeling ◽  
Outlet Temperature ◽  
Aluminum Extrusion ◽  
Scientific Approach ◽  
Simulation Results

The article presents an outline of a scientific approach for testing constitutive relations for the aluminum extrusion process. By comparing ram force, container friction, die face pressure, outlet temperature measurement during rod extrusion with corresponding simulated data, inferences can in principle be drawn with respect to the validity models. The paper indicates that simulation results from the 2D ALMA2π program are in fair agreement with measurements during extrusion of AA6060, but more work needs to be done to control thermal conditions during extrusion.

Numerical Simulation of Aluminum Extrusion Process Using Body-Fitted Grids Based Finite Volume Method

2014 ◽  
Vol 602-605 ◽  
pp. 64-68
Author(s):  
Yu Jie Zhang ◽  
Xiao Feng Gong ◽  
Rui Wang ◽  
Xiao Qing Feng
Keyword(s):  
Finite Volume Method ◽  
Finite Volume ◽  
Initial Conditions ◽  
Effective Strain ◽  
Mathematic Model ◽  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Computational Region ◽  
Coordinate Conversion ◽  
Volume Method

A mathematic model of aluminum extrusion process using body-fitted grids based finite volume method was studied and established in this paper. The basic goverment equations of the finite volume method were built, body-fitted grids were used to mesh computational region, basic goverment equations were discretized on body fitted grids directly, so complex coordinate conversion was avoided by no use of aptamer coordinate system. Initial conditions, boundary conditions and calculation processes of aluminum extrusion process finite volume method were studied and established, a program had been written based this model and a typical process of aluminum extrusion was simulated, amount of physical fields such as velocities, effective stress and effective strain rate etc. were obtained, the results were compared with that simulated by finite element method, so the feasibility and exactness of the mathematic model is proved.

Analysis of Metal Flow of Aluminum through Long Choked Die Channels

2009 ◽  
Vol 424 ◽  
pp. 145-152 ◽  
Author(s):  
Henry Sigvart Valberg
Keyword(s):  
Cross Section ◽  
Channel Wall ◽  
Metal Flow ◽  
Extrusion Process ◽  
Sliding Contact ◽  
Aluminum Extrusion ◽  
Grid Pattern ◽  
Contact Conditions ◽  
New Knowledge ◽  
Flow Through

The mechanics of metal flow through long choked die channels have been investigated in unlubricated hot aluminum extrusion. Experiments were performed in a laboratory press at an earlier occasion by letting a grid pattern introduced into the billet flow down into the choked die channel to appear adjacent to the channel wall. The grid pattern was then revealed to characterize the metal flow in the channel. A 2D-model of the extrusion process was made. The model was applied to study the conditions in the extrusion experiments and in this model good similarity was obtained with the experiment. New knowledge regarding the metal flow through a choked die channel have been obtained this way, such as; contact conditions, presence of sticking and sliding zones, friction conditions in the sliding contact zone and the velocity profile over the cross-section of the channel.

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