Finite element investigations upon the influence of pocket die designs on metal flow in aluminium extrusion

2003 ◽  
Vol 135 (2-3) ◽  
pp. 189-196 ◽  
Author(s):  
Q Li ◽  
C.J Smith ◽  
C Harris ◽  
M.R Jolly
Keyword(s):  
Finite Element ◽  
Metal Flow ◽  
Aluminium Extrusion

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

scholarly journals Evaluation of Different Tools of Precision Finishing for Cold Extruded Sun Gear With Internal-External Tooth Shapes

2021 ◽  
Author(s):  
Zuofa Liu ◽  
Xi Wang ◽  
Wenjie Feng ◽  
Jie Zhou ◽  
Zhiyuan Qu ◽  
...  
Keyword(s):  
Finite Element ◽  
Metal Flow ◽  
Commercial Production ◽  
Cold Extrusion ◽  
Forming Load ◽  
Tool Stress ◽  
Distribution Laws ◽  
Profile Accuracy ◽  
Precision Finishing ◽  
Prediction Strategy

Abstract Due to the complex metal flow in the cold extrusion of sun gear, the teeth accuracy of formed sun gear is poor. In order to improve the accuracy of the extruded sun gear, a novel precision finishing method with different tools was proposed in this study. Finite element simulations were performed using DEFORM, and a new finite element (FE) prediction strategy was developed to obtain an in-depth understanding of the deviation distribution laws of the finished sun gear. Then, the influences of different finishing tools on tooth deformation, tool stress, forming load and tooth accuracy were examined. The investigation results show that the profile accuracy of external gear can be improved from ninth to seventh class, lead accuracy can be enhanced from tenth to eighth class, and total M value deviation of internal spline is reduced to 72.3 μm by the precision finishing method with interference mandrel. Therefore, the interference mandrel is recommended as the optimal reshaping tool for commercial production of sun gears. The simulation results are well agreed with the experimental results, which verifies the feasibility of the precision finishing method and the reliability of the FE prediction strategy.

Stress and Strain Distribution in the Upsetting Process

2021 ◽  
pp. 288-301
Author(s):  
Japheth Obiko ◽  
Fredrick Madaraka Mwema
Keyword(s):  
Finite Element ◽  
Strain Distribution ◽  
Metal Flow ◽  
Stress Strain ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Contact Surfaces ◽  
Stress Behaviour ◽  
Stress And Strain Distribution ◽  
Forging Load

Numerical simulation of metal flow behaviour was studied using DeformTM3D software. The simulation process was done on X20 steel taken from the software database at 1073-1273K temperature, 10mm/s die speed, and 67% height reduction. From the simulation results, forging load, damage, and stress/strain distributions were obtained. The results show that the forging load increased with a decrease in temperature or decreased with an increase in temperature. The maximum damage values increased as the temperature increased. The obtained maximum damage values were 0.42 (1073K), 0.43 (1173K), and 0.45 (1273K). The damage distribution was inhomogeneous in the deformed cylinder. The stress/strain distributions were inhomogeneous in the deformed cylinder. The location of the maximum strain was at the centre of the deformed cylinder while the maximum stress occurred at the die-cylinder contact surfaces. The study showed that flow stress behaviour can be predicted using finite element method. This shows the feasibility of applying the finite element analysis to analyse the forging process.

Study on Cylindrical Heatsink Forging Process Considering Friction Condition

2019 ◽  
Vol 823 ◽  
pp. 141-144
Author(s):  
Tung Sheng Yang ◽  
Yong Nan Chen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Friction Factor ◽  
Testing Machine ◽  
Metal Flow ◽  
Compression Tests ◽  
Stress Strain ◽  
Element Analysis ◽  
Forging Process ◽  
Different Temperatures

The feasibility of forging of AL-1050 alloy of cylindrical heatsink under warm conditions is demonstrated in the present work. The stress-strain curves and friction factor play an important role in the cylindrical heatsink forging. The purpose of forging lubrication is to reduce friction between blank and die, and to decrease resistance of metal flow to die. The stress-strain curves at different temperatures are obtained by compressing tests. The friction factor between 1050 aluminum alloy and die material are determined at different temperatures by ring compression tests with graphite lubricants. The compressing and ring compressing tests are carried out by using the computerized screw universal testing machine. The finite element method is used to investigate the forming characters of the forging process. To verify the prediction of FEM simulation in the cylindrical heatsink forging process, the experimental parameters such as stress-strain curves and fiction factor, are as the input data during analysis. Maximum forging load and effective stress distribution are determined of the heatsink forging, using the finite element analysis. Finally, the cylindrical heatsink parts are formed by the forging machine under the conditions using finite element analysis.

Application of FEM Modeling to Simulate Metal Flow in Forging a Titanium Alloy Engine Disk

1983 ◽  
Vol 105 (4) ◽  
pp. 251-258 ◽  
Author(s):  
S. I. Oh ◽  
J. J. Park ◽  
S. Kobayashi ◽  
T. Altan
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Titanium Alloy ◽  
Metal Flow ◽  
The Finite Element Method ◽  
Fem Modeling ◽  
Forging Process ◽  
Deformation Mechanics ◽  
Effects Of Temperature ◽  
Element Method

The isothermal forging of a titanium alloy engine disk is analyzed by the rigid-viscoplastic finite element method. Deformation mechanics of the forging process are discussed, based on the solution. The effects of temperature and heat conduction on the forging process are also investigated by coupled thermo-viscoplastic analysis. Since the dual microstructure / property titanium disk can be obtained by controlling strain distribution during forging, the process modeling by the finite element method is especially attractive.

Study on Heading and Thread-Rolling Processes of Magnesium Alloy Screws

2013 ◽  
Vol 535-536 ◽  
pp. 322-325 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Kai Neng Hwang ◽  
Chia Yu Chang
Keyword(s):  
Finite Element ◽  
Magnesium Alloy ◽  
Flow Pattern ◽  
Effective Strain ◽  
Metal Flow ◽  
Rolling Process ◽  
Die Set ◽  
Thread Rolling ◽  
Experimental Values ◽  
Two Stages

This study is to investigate the effects of the process parameters on the heading load and metal flow pattern during heading and thread-rolling processes of LZ91 magnesium alloy screws. A heading process composed of two stages is proposed. The material flow pattern of the billet inside the die is analyzed using the finite element analyses. The effects of the upper die velocity, temperatures and friction factors on the heading loads and product quality are discussed. On the other hand, in the thread-rolling process, the effects of the friction factor on the effective stress, effective strain, and tooth height are investigated. Finally, heading and thread-rolling experiments are conducted using a self-designed die set and a lubricant of MoS2. The experimental values are compared with the simulation results to verify the validity of the finite element models and the proposed heading procedures.

Study on the Finite Element Numerical Simulation of Automobile Crossbeam Stamping Forming

2011 ◽  
Vol 55-57 ◽  
pp. 2104-2108
Author(s):  
Xiao Chun Ma ◽  
Wei Bing Shen ◽  
Yi Qiang Zhuang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Optimal Parameter ◽  
Thickness Distribution ◽  
Metal Flow ◽  
Forming Limit Diagram ◽  
Design Parameters ◽  
Forming Limit ◽  
Explicit Finite Element ◽  
Finite Element Numerical Simulation

This paper is concerned with the quantitative effect of design parameters on the stamping process of automobile crossbeam. The considered parameters in this paper are the friction coefficient, the die fillet radius and the blank holding force, which greatly affect the metal flow during stamping. Based on the finite element numerical simulation, the stamping shaped process of the automobile crossbeam is numerical simulated with the explicit finite element method with various parameters by dint of Dynaform software. According to the simulation results, the forming limit diagram(FLD) and the wall thickness distribution of cloud on the stamping processes are technologically analyzed, the reasons and control methods of wrinkling are also pointed out, and then the optimal parameter combination of the automobile crossbeam is obtained by orthogonal experiments. It is noted that the parametric study of design parameters such as µ , BHF and RD are very important in the process design of the complicated member.

FE Simulation of Die Forging Process for High Pressure Valve Body

2013 ◽  
Vol 763 ◽  
pp. 207-210
Author(s):  
Yang Yang ◽  
Li Wen Zhang ◽  
Zhi Zhu ◽  
Jian Lin Zhang
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Flow Field ◽  
Fe Simulation ◽  
Metal Flow ◽  
Valve Body ◽  
Forging Process ◽  
Die Forging ◽  
Good Guide ◽  
Deform 3D

In this paper, based on the finite element (FE) software Deform 3D, the simulation of the die forging process of a high pressure valve body was conducted. The deformation field and the metal flow field of billet were obtained and analyzed in detail. In addition, the effect of upsetting depth on the die forging process of high pressure valve body was also discussed. This study can provide a good guide for the following researches and practical industry.

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