Finite Element Simulation for the Surface Flaw in Tube Open-die Cold Extrusion Process

Extending extrusion process of semisolid AA2017 alloy was achieved. Metal flow during the process was analyzed by the finite element simulation. It was shown that alloy flow velocity decreases gradually from the center part to the sides of the mould, sometimes a transitional turbulence region appears in the middle. A smaller declining angle θ and without step d is suggested in the design mould. Alloy flow velocity at the center of the forming region decreases linearly with increases of the extending ratio s1/s0.

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Optimization approach for processing design in the extrusion process of plastic profile with metal insert

e-Polymers ◽

10.1515/epoly.2012.12.1.353 ◽

2012 ◽

Vol 12 (1) ◽

Cited By ~ 1

Author(s):

Yue Mu ◽

Guoqun Zhao ◽

Xianghong Wu

Keyword(s):

Neural Network ◽

Genetic Algorithm ◽

Finite Element ◽

Finite Element Simulation ◽

Extrusion Process ◽

Optimization Approach ◽

Processing Conditions ◽

Metal Insert ◽

Element Simulation ◽

Plastic Profile

AbstractThe extrusion process of plastic profile with metal insert is a kind of novel and advanced plastic processing method which requires rigorous control on processing conditions to ensure the quality and performance of final products. However, it is still difficult to achieve an optimal processing design by using traditional “trial and error” method. An optimization approach for the processing design in the extrusion process of plastic profile with metal insert is proposed based on finite element simulation, back propagation neural network and genetic algorithm in the study. The finite element simulation is conducted to predict polymer melts flow in the extrusion process. The simulated results are extracted for the establishment of neural network. The genetic algorithm is performed for the search of globally optimal design variable with its objective function evaluated by using the established neural network model. The proposed approach is adopted for the optimization of processing conditions in the extrusion process of plastic profile with metal insert. According to the flow balance principle, the uniformity of outlet flow distribution is taken as the optimization objective with a constraint condition on the maximum shear stress. The optimization of two processing parameters including the volume flow rate and the metal insert moving velocity is conducted in the extrusion process of plastic profile with metal insert and the optimization objective is successfully achieved.

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Finite Element Simulation of Backward Micro Extrusion for Annealed Copper

Volume 2: Advanced Manufacturing ◽

10.1115/imece2018-86755 ◽

2018 ◽

Author(s):

Md Mosleh Uddin ◽

Debabrata Mondal ◽

Paul D. Herrington

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Extrusion Process ◽

Simulation Software ◽

Uniaxial Compression Test ◽

Micro Forming ◽

Element Simulation ◽

Micro Parts ◽

Annealed Copper ◽

Bulk Production

The growing demand of miniaturized products is tremendously influencing the progress of micro-forming technologies. The implementations of micro technologies in the field of microelectronics, sensors, and medical equipment necessitate versatile micro-forming processes. These processes facilitate the bulk production of micro parts with higher precision, minimum material waste, and better surface finish. However, micro-forming technologies are still expensive due to the limitations of traditional materials and stringent size requirements. Finite element simulations are being widely used to analyze the manufacturing process parameters before going into production. In this research, a backward micro-extrusion process is simulated for annealed copper by using commercial Finite element simulation software. The effects of different punch diameters, friction coefficients, punch velocities on the load-displacement curves and the resulting strain distributions are investigated. To overcome limitations of the post-yield hardening data from the uniaxial compression test, the Ramberg-Osgood model is proposed to predict the responses at the higher plastic strain.

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