Modeling of Ram Extrusion Process and Optimal Die Design

1996 ◽  
Author(s):  
Qingwen Deng ◽  
Yuyi Lin
Keyword(s):  
Analytical Model ◽  
Model Development ◽  
Optimization Procedure ◽  
Powdered Material ◽  
Extrusion Process ◽  
Die Design ◽  
Experimental Procedure ◽  
Extrusion Die ◽  
Powdered Coal ◽  
Good Agreement

Abstract This paper presents a one-dimensional analytical model of the ram extrusion process of a powdered material and a procedure for optimizing the shape of the extrusion die. Powdered coal mixed with water and asphalt was used as the extrudate material in the model development. The analytical model relates the pressure at the entrance of the die to the exit pressure of the die. Certain key parameters of the model were obtained from experiments. The comparison of the inlet pressure derived from the analytical model and the value obtained from the experimental procedure shown a good agreement. Optimization algorithms were applied to generate the ideal die shape. The objective is to minimize the power consumed in the extrusion process, while maintaining maximum strength for the extrudates. It is concluded from the study that the model and the optimization procedure developed for the model can be used in extrusion studies of other powdered materials.

scholarly journals Liquid Nitrogen in The Industrial Practice of Hot Aluminum Extrusion: Experimental and Numerical Investigation

2021 ◽  
Author(s):  
Riccardo Pelaccia ◽  
Barbara Reggiani ◽  
Marco Negozio ◽  
Lorenzo Donati
Keyword(s):  
Liquid Nitrogen ◽  
Extrusion Process ◽  
Die Design ◽  
Design Stage ◽  
Industrial Practice ◽  
Cooling Channels ◽  
Ram Speed ◽  
Aluminium Extrusion ◽  
Liquid Nitrogen Cooling ◽  
Good Agreement

Abstract Nowadays, the liquid nitrogen cooling in aluminium extrusion is a widely adopted industrial practice to increase the process productivity as well as to improve the extruded profile surface quality by reducing the profile exit temperatures. The cooling channels are commonly designed on the basis of die maker experience only, usually obtaining modest performances in terms of cooling efficiency. Trial-and-error approach is time and cost consuming, thus providing a relevant industrial interest in the development of reliable numerical simulations able to foresee and optimize the nitrogen cooling effect during the die design stage. In this work, an extensive experimental campaign was performed during the extrusion process of an AA6060 industrial hollow profile, in different conditions of nitrogen flow rate and ram speed. The monitored data (die and profile temperatures and extrusion load) were compared with the outputs of a fast and efficient numerical model proposed by the authors, and developed in the COMSOL Multiphysics code, able to compute not only the effect of nitrogen liquid flow but also the gaseous condition. The results of the simulations showed a good agreement with experimental data and evidenced how far was the experimental cooling channel design from an optimized condition.

Newest Developments on the Manufacture of Helical Profiles by Hot Extrusion

2011 ◽  
Author(s):  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Twist Angle ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
3D Fem ◽  
Extrusion Die ◽  
Contour Accuracy ◽  
Application Fields ◽  
Twisting Angle ◽  
Screw Rotors

The paper presents a new innovative direct extrusion process, Helical Profile Extrusion (HPE), which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction on the material flow in the extrusion die in order to find out the optimal parameters with reference to the twisting angle and contour accuracy. By means of FEM, the profile shape could be optimized by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. The accuracy of the profile contour could be improved significantly. However, increasing the twist angle is limited due to geometrical aspects.

Numerical Simulation and Die Design for Vibration Extrusion of Spur Gear

2012 ◽  
Vol 580 ◽  
pp. 37-41
Author(s):  
Qiong Lin ◽  
Bin Meng ◽  
Qing Hua Yang
Keyword(s):  
Numerical Simulation ◽  
Flow Characteristic ◽  
Metal Flow ◽  
Spur Gear ◽  
Extrusion Process ◽  
Die Design ◽  
Forming Process ◽  
Extrusion Die ◽  
Die Structure ◽  
Metal Extrusion

The numerical simulation for spur gear vibration extrusion is performed in this paper. The metal flow characteristic and load-stroke relationship during forming process is analyzed and then compared with traditional metal extrusion process. The results revealed the axial vibration of cavity die can both reduce forming load and benefit for metal flow, which could achieve better forming quality. Finally according to the processing requirements, the vibration generator and whole extrusion die structure is designed.

scholarly journals EFFECTS OF GUIDING CHAMBER ON WELDING PRESSURE IN HOLLOW EXTRUSION DIE DESIGN OF AA7075

2018 ◽  
Vol 54 (5A) ◽  
pp. 191
Author(s):  
Do Anh Tuan
Keyword(s):  
Aluminum Alloy ◽  
Extrusion Process ◽  
Die Design ◽  
Design Parameters ◽  
Element Analysis ◽  
Suitable Material ◽  
Hollow Section ◽  
Extrusion Die ◽  
Welding Pressure ◽  
Aluminum Alloy Tube

Porthole die extrusion has a great advantage in the forming of hollow section of aluminum alloy tube. This paper aims at the development of an extruding seam square tube of AA7075 high strength aluminum alloy. In order to increase the welding pressure of the hollow AA7075 tube in extrusion process, a special die feature has been created. Several different proportions of chamber structure in outlet of extrusion die have been designed. The finite element analysis software DEFORM 3D to analyze various design parameters on the load – displacement and the welding pressure have been studied. In this study, a different high proportion in material guiding chamber has been defined. The results showed that if a suitable material guiding chamber has been built then welding pressure can be increased rapidly. When the ratio of chamber height and length is 2:1 the increased welding pressure is the best.

Finite Element Analysis and Die Design of Extrusion Processes of Radial-Finned Heat Sink

2011 ◽  
Vol 264-265 ◽  
pp. 30-35
Author(s):  
Dyi Cheng Chen ◽  
Jhih Ming Chen ◽  
Ming Wei Guo ◽  
Chih Hsuan Jao ◽  
Wen Jong Chen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Heat Sink ◽  
Extrusion Process ◽  
Die Design ◽  
Element Analysis ◽  
Extrusion Die ◽  
Different Types ◽  
Finite Element Package ◽  
Manufacturing Methods

There are many different types of manufacturing methods for heat sink fins in the current market. The aim of this study is to design an extrusion die for a radial-finned heat sink using a commercial finite element package, DEFORMTM 3D. We then conduct a series of simulation analyses with different variables such as friction factor, ram velocity, and fin gate stage of the die to evaluate the methods of decreasing the warping in the extrusion process. The die is assumed as a rigid body in the analyses. The results confirm the suitability of DEFORMTM 3D to design an extrusion die achieving a lower warping behavior of the radial-finned heat sink.

Accurate Simulation of the Four Modes of Post-Die Extrudate Shape Distortion

2021 ◽  
Vol 36 (1) ◽  
pp. 69-78
Author(s):  
M. Gupta
Keyword(s):  
Layer Structure ◽  
Die Design ◽  
Velocity Variation ◽  
Shape Distortion ◽  
Exit Velocity ◽  
Extrusion Die ◽  
Combined Flow ◽  
Extruded Product ◽  
Simulation Results ◽  
Extrudate Distortion

Abstract A combined flow, thermal and structural analysis is employed to simulate post-die extrudate distortion in different profile dies. All four factors which can cause extrudate distortion, namely, nonuniform exit velocity distribution, extrudate shrinkage, extrudate draw down, and deformed shape of the calibrator or sizer profile, are simulated. To analyze the effect of exit velocity variation on extrudate distortion, the parameterized geometry of a simple profile die is optimized using an extrusion die optimization software. The simulation results presented for a bi-layer profile die successfully demonstrate how gradually changing profile shape in successive calibrators/sizers can be used to simplify the die design for extrusion of complex profiles. The predicted extrudate shape and layer structure for the bi-layer die are found to accurately match with those in the extruded product.

scholarly journals EFFECT OF EXTRUSION PROCESS PARAMETERS ON MECHANICAL PROPERTIES OF 3D PRINTED PLA PRODUCT

2021 ◽  
Vol 6 (2) ◽  
pp. 119
Author(s):  
Nanang Ali Sutisna ◽  
Rakha Amrillah Fattah
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Extrusion Process ◽  
Experimental Procedure ◽  
Fused Deposition ◽  
Novel Approach ◽  
Deposition Modeling ◽  
3D Printed ◽  
3D Digital Models

The method of producing items through synchronously depositing material level by level, based on 3D digital models, is named Additive Manufacturing (AM) or 3D-printing. Amongs many AM methods, the Fused Deposition Modeling (FDM) technique along with PLA (Polylactic acid) material is commonly used in additive manufacturing. Until now, the mechanical properties of the AM components could not be calculated or estimated until they've been assembled and checked. In this work, a novel approach is suggested as to how the extrusion process affects the mechanical properties of the printed component to obtain how the parts can be manufactured or printed to achieve improved mechanical properties. This methodology is based on an experimental procedure in which the combination of parameters to achieve an optimal from a manufacturing experiment and its value can be determined, the results obtained show the effect of the extrusion process affects the mechanical properties.

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.

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