Study on the Guiding Chamber Effect on Welding Pressure in Hollow Extrusion Die Design

2010 ◽  
Author(s):  
Quang-Cherng Hsu ◽  
Ping-Hsun Tsai
Keyword(s):  
Aluminum Alloy ◽  
Flow Behavior ◽  
Metal Flow ◽  
Die Design ◽  
High Yield ◽  
Design Parameters ◽  
Element Analysis ◽  
Suitable Material ◽  
Extrusion Die ◽  
Welding Pressure

In order to increase the welding pressure of the hollow Al7075 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. Comparing to 6000 series, 7000 series aluminum alloy have good material properties, including excellent strength and toughness especially for hollow aluminum extrusion products in terms of Al7075. However, in extruded hollow aluminum alloy products, the industry’s common use is 6000 series material, except for indirectly extruded seamless pipe, Al7075 can be found. This is because of less welding pressure can be provided by using the traditional die structures in Al7075 hollow products. Therefore, to use the directly extruded seam tube of Al7075 in high-yield and high-quality, to increase the welding pressure and improve the quality of welding products becomes a very important issue. In this study, a different high proportion in material guiding chamber has been defined. The same angle both on the exit of female die and the bearing of male die which can be integrated into a material guiding chamber has been designed. Therefore, the welding pressure can be increased due to the change of metal flow behavior that is after a complete fill in material guiding chamber, and then metal can flow out of die bearing surface. The results showed that welding pressure can be increased rapidly if a suitable material guiding chamber has been built. Among them, the ratio of chamber height and length is 2:1; the increased welding pressure is most significant.

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.

Forging Process Analysis of 6061 Aluminum Alloy Motorcycle Brake Parts

2021 ◽  
Vol 901 ◽  
pp. 176-181
Author(s):  
Tung Sheng Yang ◽  
Chieh Chang ◽  
Ting Fu Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Process Analysis ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Die Design ◽  
Element Analysis ◽  
Forging Process

This paper used finite element analysis of metal forming to study the forging process and die design of aluminum alloy brake parts. According to the process parameters and die design, the brake parts were forged by experiment. First, the die design is based on the product size and considering parting line, draft angle, forging tolerance, shrinkage and scrap. Secondly, the finite element analysis of metal forming is used to simulate the forging process of aluminum alloy brake parts. Finally, the aluminum alloy brake levers with dimensional accuracy and surface hardness were forged.

Effects of Welding Chamber Step on Extrusion Process of a Complex Hollow Profile

2010 ◽  
Vol 148-149 ◽  
pp. 1684-1688 ◽  
Author(s):  
Hao Chen ◽  
Guo Qun Zhao ◽  
Cun Sheng Zhang ◽  
Jiang Wei Liu
Keyword(s):  
Quality Control ◽  
Numerical Model ◽  
Product Quality ◽  
Cross Section ◽  
Metal Flow ◽  
Extrusion Process ◽  
Weld Quality ◽  
Extrusion Die ◽  
Temperature Distributions ◽  
Welding Pressure

The extrusion die is of great importance in the quality control of profile production. Yet in practice, the design of extrusion die is mainly dependent on the experience and intuition of die designers, which is difficult to guarantee product quality and productivity. In this paper, a numerical model was developed based on HyperXtrude with an attempt to investigate the effects of the shape of the welding chamber on metal flow and weld quality. The porthole dies with different steps of welding chamber were designed and applied to extrude an identical profile. Numerical results showed that with an increasing step of welding chamber, more uniform velocity and temperature distributions in the cross-section of the extrudate were observed. In addition, the weld quality was improved owing to increasing welding pressure, when adopting the multi-step welding chamber.

Comparison of Metal Flow Characteristics in Aluminium Extrusion Die using Numerical Simulations for AA6063 and AA7075

2021 ◽  
Vol 13 (2) ◽  
Author(s):  
V.N.S.U. Viswanath Ammu ◽  
Samrat Ambade ◽  
N.S. Anas ◽  
R.N. Chouhan ◽  
Anupam Agnihotri
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Flow Characteristics ◽  
Die Design ◽  
Maximum Speed ◽  
Simulation Studies ◽  
Industrial Sectors ◽  
Extrusion Die ◽  
Aluminium Extrusion ◽  
Alloy Properties

Aluminium extruded profiles are used for light weight structures used in architecture, transportation, aerospace, industrial sectors etc. Increasing use of profiles for applications has been driving extruiders to focus on reliable techniques to produce profile that meet consistent quality. In aluminium extrusion, profitability can be achieved by pushing maximum number of billets i.e maximum speed during production. However, in the shopfloor different aluminium alloys and geometries are limited by manufacturibility limitations which based on alloy properties and metal flow charcateritics. Hence, product quality is largely dependant on the closer control of metal flow charcateritics that can be compensated by right quality aluminium billet and die design paramaters. In this regard, numerical simulation studies have been adopted prior to production to ensure the consistent and reliable quality of profiles. In this technical communication, metal flow characteristics such as velocity, temperature and strain rate in an extrusion die were compared using numerical simulation studies for two alloys namely AA6063 and AA7075.

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.

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