FEM Simulation of the Whole Circle of Aluminum Hot Extrusion Using Circular Dies With Different Extrusion Angle

2006 ◽  
Author(s):  
A. Lontos ◽  
K.-D. Bouzakis ◽  
G. Demosthenous ◽  
A. Baldoukas
Keyword(s):  
Product Quality ◽  
Process Parameters ◽  
Surface Condition ◽  
Fem Simulation ◽  
Hot Extrusion ◽  
Die Design ◽  
Work Piece ◽  
Billet Temperature ◽  
Extrusion Die ◽  
Ram Speed

On of the most typical forming processes used for the production of long, straight semi-finished products in the form of various section geometries is extrusion. Hot extrusion is a thermo-mechanical process whish involves complicated interactions between process parameters, tooling and deforming material /1,2/. In the present paper, FEM simulation is performed in the aluminum extrusion using circular dies with different geometries in order to extract quantitative simulating results regarding various forming parameters. Most specifically the parameters that are investigated are the die design-geometry, the process parameters (i.e. ram speed, container temperature, billet temperature) and the product quality (i.e. extruded shape, surface condition). The finite element modeling is based on 3D simulation tools using the DEFORM 3D software /3–5/. The used work piece is the aluminum AA6061 in cylindrical form with a diameter of 14 mm. The used material for the extrusion die is the hot work steel AISI H13. The geometry of the die is circular with a variation in die angle. The container and the billet temperature will vary from 450 to 550 degrees, and the mandrel (ram) speed will be at the range of 2 mm/sec. On the basis of simulating results such as pressure distribution on the extrusion die, effective stresses on the billet and product quality, new and improve die geometry will be introduced. Although the simulation problem is an axisymmetric one the authors decide to proceed with 3D FEM simulation in order to examine and verify the 3D simulating results. This paper is the first part of a further research project in which more complicated die geometries will be used as simulating and experimental specimens. In addition to simulating results, experimental results will be presented in the next few months.

Quantitative Analysis of the Extrusion Process of AZ31 Magnesium Alloy Based on Rough Set Theory and 3DFEM Simulation

2010 ◽  
Vol 455 ◽  
pp. 200-205 ◽  
Author(s):  
Yan Lou
Keyword(s):  
Product Quality ◽  
Set Theory ◽  
Rough Set ◽  
Rough Set Theory ◽  
Processing Parameters ◽  
Extrusion Process ◽  
Die Design ◽  
Average Weight ◽  
Billet Temperature ◽  
Ram Speed

The effect of extrusion process on the quality of AZ31 magnesium extrudate was performed, by data mining from 3DFEM simulation and Rough Set Theory(RST). The weight of the effect of processing parameters and die structures can be obtained to predict the product quality, to optimize the extrusion processing and the die design. The results show that the effect of the billet temperature on the product quality is dominate, and its average weight is 0.25. The second important parameter is the ram speed and its average weight is 0.21. The third is the extrusion ratio. Its average weight is 0.18. In addition, it was also found that the effect of the die characteristic parameters on the extrudate is insignificant. Finally, the rationality of the weight of effect was verified through experiments.

Selection of Optimal Hot Extrusion Process Parameters for AA6061-Fly Ash Composites

2018 ◽  
Vol 5 (1) ◽  
pp. 52-67 ◽  
Author(s):  
Sarojini Jajimoggala
Keyword(s):  
Process Parameters ◽  
Process Development ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Billet Temperature ◽  
Temperature Changes ◽  
H13 Tool Steel ◽  
Half Angle ◽  
Ram Speed ◽  
Simulation Parameters

The simulation of hot extrusion process is a challenging problem in process modeling because of very large deformations, strain rates and temperature changes during the process. The process development in industrial extrusion is to a maximum extent based on trial and error and often involves full size experiments. Numerical simulations can replace most of these experiments, which are often both time consuming and expensive. Hence in the present work, attempt has been made to simulate hot extrusion process. AA6061-flyash Metal Matrix Composite(MMC) as billet, H13 tool steel as the die, 400oC as billet temperature and extrusion ratio of 25:4 are used as simulation parameters. Simulation is performed using software DEFORM 3D by varying ram speed, Cone Half Angle (CHA) and friction coefficient with extrusion load. The effects of change of process parameters were observed and optimal process parameters were selected.

Influence of Billet Quality on Hot Extrusion Die Life and its Relationship with Process Parameters

2009 ◽  
Vol 83-86 ◽  
pp. 866-873 ◽  
Author(s):  
S.S. Akhtar ◽  
Abul Fazal M. Arif ◽  
A.K. Sheikh
Keyword(s):  
Process Parameters ◽  
Hot Extrusion ◽  
Die Design ◽  
Grain Structure ◽  
Homogeneous Distribution ◽  
Microstructural Investigation ◽  
Billet Quality ◽  
Extrusion Die ◽  
Die Life ◽  
Die Service Life

Apart from other factors such as die design and manufacturing, heat treatment, working conditions etc, performance of hot extrusion die can directly be related to the billet quality used in the extrusion press. The purpose of this paper is to investigate the effect of Al-6063 billet source (primary or secondary) on extrusion die life based on microstructural and statistical analyses. In microstructural investigation, secondary (remelt) billet cast in-house at local extrusion plant is compared with primary (smelter) billet by applying different material characterization techniques including optical microscopy, hardness measurement, X-ray diffraction (XRD) analysis, and energy dispersive spectroscopy (EDS). The statistical study is based on the failure history of some 53 hollow-profile dies in which the effect of billet quality on various measurable process parameters including extrusion ratio, billet temperature, exit temperature and repeated nitriding is analysed and related with useful die service life. Comparatively coarse grain structure, non-homogeneous distribution of secondary phases, and high hardness in the case of secondary billet were found responsible for poor die performance as observed in statistical investigation of failed dies. Two types of regression models are also proposed for prediction of die life in terms of secondary billets’ usage and measurable influencing parameters. Using current results, some suggestions during in-house billet preparation of secondary billets have been devised for improved die life.

FEM Simulation on Extrusion of Magnesium Alloys

2012 ◽  
Vol 268-270 ◽  
pp. 492-495
Author(s):  
Guo Ping Chen ◽  
Jun Deng ◽  
Shui Wen Zhu
Keyword(s):  
Large Deformations ◽  
High Strain ◽  
Metal Flow ◽  
Fem Simulation ◽  
Transient State ◽  
Process Conditions ◽  
Strain Rates ◽  
Billet Temperature ◽  
Finite Element Software ◽  
Ram Speed

Extrusion of magnesium billets is associated with large deformations, high strain rates and high temperatures, which results in computationally challenging problems in process simulation. A simulation was carried out using the finite element software ABAQUS. The computed model was rotational symmetric and built up by meshing. Computed parameters including material characteristics and process conditions (billet temperature. reduction ratio, and ram speed) were taken into consideration. The distributions of temperature were different comparing the transient-state extrusion with the steady-state extrusion. The extrusion simulation was the reliable predictions of strain rate, effective strains, effective stresses and metal flow velocity in an AZ31 billet during direct extrusion.

Square Tube Manufacturing by forward Extrusion of AA7075 with Porthole Die

2012 ◽  
Vol 579 ◽  
pp. 92-100 ◽  
Author(s):  
Quang Cherng Hsu ◽  
Kun Hong Kuo ◽  
Ping Hsun Tsai
Keyword(s):  
High Strength ◽  
Die Design ◽  
Extrusion Force ◽  
Billet Temperature ◽  
Forward Extrusion ◽  
Die Stress ◽  
Die Set ◽  
Ram Speed ◽  
The One ◽  
Welding Pressure

The proposed paper aims at the development of extruding seam square tube of AA7075 high strength aluminum alloy by simulation and experiment. There are several factors related to extrusion load such as billet temperature, billet dimension, flow stress, die cavity and product geometry. The extrusion loads and die stresses for hot extruding square tube with respect to different product have been investigated. Since AA7075 behaves high forming resistance comparing to AA6063 and AA6061, the product design and die design should be modified in order to meet with the limitation of extrusion machinery. Moreover, AA7075 has high thermal welding crack behavior by comparing to AA7003. Therefore, In order to provide high contact pressure enough to conduct solid welding for the split AA7075 materials in welding chamber, the specific die cavity design has been finished. Then, the solid welding pressure can be increased. The research results show that under the same forming conditions such as fixed ram speed and billet temperature, the extrusion force for the product with thick thickness is small than the one with thin thickness. The same result was obtained for die stress. A square tube extrusion experiment has been conducted by installing die set into forward extrusion machinery. The experiment and simulation results have been compared and discussed.

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.

Die Design in Fine-Piercing Process by Chamfering Cutting Edge

2010 ◽  
Vol 443 ◽  
pp. 219-224 ◽  
Author(s):  
Suthep Yiemchaiyaphum ◽  
Masahiko Jin ◽  
Sutasn Thipprakmas
Keyword(s):  
Process Parameters ◽  
Flow Analysis ◽  
Fem Simulation ◽  
Material Flow Analysis ◽  
Cutting Edge ◽  
Die Design ◽  
The Finite Element Method ◽  
Sheet Metal Parts ◽  
Secondary Operations ◽  
Die Roll

The hole quality on sheet metal parts is directly dependent on the die design and process parameters. In conventional piercing process, the secondary operations such as shaving, reaming and grinding are needed for manufacturing the precise-dimensioned holed parts without any cracks, resulting in the increase of both production time and costs. The fine-piercing process, referenced to the fine-blanking principle, is used to produce the precise-dimensioned holed parts with smooth-cut surfaces over the whole material thickness in a single operation. However, it is difficult to achieve the suitable die design and process parameters for meeting the part requirements. In this study, the die design by chamfering punch cutting edge was investigated on both the experiments and the finite-element method (FEM). The results were compared with the results obtained when the conventional die design with the punch cutting-edge radius was used. The FEM-simulation results showed the amount of die-roll, smooth-cut surface, and cracks agreed well with the experimental results. The results showed that an application of punch cutting-edge chamfer results in a superior fine-pierced hole surface could be achieved. Furthermore, the mechanism and effects of the punch cutting-edge chamfer have been theoretically clarified on basis of the material-flow analysis and stress distribution.

Analyses of Plastic Flow and Die Design during Hot Extrusion of Magnesium Alloy Strips

2010 ◽  
Vol 443 ◽  
pp. 98-103 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Shih Ming Tu
Keyword(s):  
Magnesium Alloy ◽  
Plastic Flow ◽  
Thickness Distribution ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
Thin Strip ◽  
Compression Tests ◽  
Ram Speed ◽  
Product Thickness

This study involves analyses and experiments of hot extrusion of magnesium alloy strips. Hot compression tests were firstly conducted to obtain the magnesium alloy’s plastic flow stresses at high temperatures. These data are used in the finite element simulations of the thin strip extrusion process. Using the FE simulations, the flow pattern of the magnesium alloy billet within the die, the temperature variation and the thickness distribution at the die exit were analyzed. The effects of different die bearing height design, initial billet temperatures and ram speed on the extrusion load, the temperature at the die exit and the product thickness distribution were also discussed. Finally, hot extrusion experiments were conducted and the experimental values of the extrusion load and dimensions of the products were compared with the analytical values to validate the analytical model. Sound products were obtained using the best designed bearing heights and other appropriate extrusion conditions.

Uniform Wearing Optimum Design of Extrusion Die Profile

2007 ◽  
Vol 353-358 ◽  
pp. 2695-2698 ◽  
Author(s):  
Lei Gang Wang ◽  
Xian Ping Sun ◽  
Yao Huang
Keyword(s):  
Neural Network ◽  
Genetic Algorithm ◽  
Bp Neural Network ◽  
Fem Simulation ◽  
Hot Extrusion ◽  
Reference Points ◽  
Wear Depth ◽  
Optimum Result ◽  
Extrusion Die ◽  
Die Profile

Die wear is regarded as a crucial factor which affects die life and quality of products. In hot extrusion process, finite-element method (FEM), BP neural network and genetic algorithm were combined together to optimize extrusion die profile which yielded more uniform wear depth distribution on die profile. A method of B-spline function interpolation was used to describe extrusion die profile. The temperature, pressure and velocity field of nodes that lied on extrusion die profile were gained by FEM simulation. Wear depth of extrusion die profile was calculated by modified Archard theory. The results were used to train BP neural network, so that nonlinear mapping relations between reference points of die profile and wear depth were obtained. In order to gain uniform wear depth, genetic algorithm was applied to optimize extrusion die profile. Optimum result, compared with common conical die profile, reduced wear depth of extrusion die and improved service life. At the same time, the optimal result accorded with practical conditions.

scholarly journals MULTIPLE PROCESS PARAMETER OPTIMIZATION OF FORWARD EXTRUSION PROCESS ON AA 2024

2021 ◽  
Vol 13 (2) ◽  
pp. 63-75
Author(s):  
Anupama Francy Kothasiri ◽  
◽  
Srinivasa Rao Chalamalasetti ◽  
Gopalakrishnaiah Peteti ◽  
◽  
...  
Keyword(s):  
Coefficient Of Friction ◽  
Parameter Optimization ◽  
Process Parameters ◽  
Extrusion Process ◽  
Work Piece ◽  
Extrusion Force ◽  
Input Process ◽  
Level 3 ◽  
Level 1 ◽  
Ram Speed

Extrusion is a simple metal forming process in which a block of metal is forced through a die orifice with a certain shape under high pressure. This extrusion process is influenced by many process parameters such as die angle (DA), ram speed (RS), coefficient of friction (COF), Extrusion ratio, Die land height, work piece diameter and length, material properties etc. In extrusion process, extrusion force is crucial parameter, the flow of metal and hence the extrusion force is significantly influenced by the above parameters which results in quality of the product. The present study numerically investigates the influence of major process parameters such as die angle, ram speed, coefficient of friction on the extrusion process. The AA2024 material is chosen as work piece material and the extrusion force and damage is considered as the output responses. The input process parameters are varied in three levels (Level - 1: 10° DA, 1.6mm/min RS, 0.06 COF; Level - 2: 20° DA, 3.2mm/min RS, 0.08 COF; Level - 3: 30° DA, 4.8mm/min RS, 0.01 COF). Numerical simulations are performed by using DEFORM 3D software. The simulations are conducted as per L27 orthogonal array. From the results it is observed that Increase of die angle, ram speed and coefficient of friction increases the extrusion force. The die angle has highest (86.45%) influence on the extrusion force, then after ram speed (6.60%). The coefficient of friction has insignificant influence (0.55%). It is also noticed that the damage is considerable after the 20° die angle. A multi parameter optimization is also done by using the Grey relation analysis by considering the equal weightage of extrusion force and damage. The optimum levels of input process parameters for the minimum extrusion force and damage is DA level 1, RS level 1, and COF level 3.

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