Effect of Process Parameters on the Microstructure Homogeneity of AA6082 Aluminum Alloy Deformed by Twist Extrusion

2013 ◽  
Author(s):  
V. S. Senthil Kumar ◽  
U. Mohammed Iqbal
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Effective Strain ◽  
Extrusion Process ◽  
Work Piece ◽  
Hardness Testing ◽  
Twist Extrusion ◽  
Experimental Values ◽  
3D Software ◽  
Deform 3D

Twist extrusion is a severe plastic deformation in which the rectangular shaped work piece is extruded through a die with a twist channel. In this work the twist extrusion process of AA6082 T6 aluminum samples were carried out to investigate the effects of process parameters like temperature and deformation passes on the microstructure homogeneity. The results indicate that the grain refinement of AA 6082 T6 aluminum alloy leads to inhomogeneous microstructure after one twist extrusion pass. On further extrusion passes the inhomogeneity in the microstructure is found to be disappeared. The homogeneity of the distribution of the deformation was confirmed by micro hardness testing. Finite element modeling has been performed in DEFORM 3D software for determining the homogeneity of the effective strain distribution which agreed well with the experimental values.

Plastic Deformation Simulation on Compound Twist Extrusion Process for Metal Materials

2013 ◽  
Vol 291-294 ◽  
pp. 2676-2679 ◽  
Author(s):  
Yong Zhi Li ◽  
Xue Fei Du
Keyword(s):  
Plastic Deformation ◽  
Severe Plastic Deformation ◽  
Effective Strain ◽  
Extrusion Process ◽  
Ultrafine Grained ◽  
Twist Extrusion ◽  
The Subject ◽  
Intensive Investigation ◽  
3D Software ◽  
Deform 3D

Severe plastic deformation（SPD）methods have been the subject of intensive investigation for preparing bulk ultrafine-grained materials in recent years. This paper introduces a new severe plastic deformation (SPD) process named as C-TE process which combines the Twist Extrusion with Extrusion against the asymmetric deformation of TE process. and the distribution of effective strain and stress of the sample and the variation of load with time and its influence on the deformation were investigated by computer simulation with Deform-3D software . The results reveal that C-TE process can significantly slow uniform phenomenon,and a sample of homogeneous deformation can be obtained by the improved process.

Influence of Heating Models on Necking Deformation during Tube Extrusion Process

2011 ◽  
Vol 189-193 ◽  
pp. 1778-1781 ◽  
Author(s):  
Gui Hua Liu ◽  
Yong Qiang Guo ◽  
Zhi Jiang
Keyword(s):  
Temperature Gradient ◽  
Material Flow ◽  
Extrusion Process ◽  
Work Piece ◽  
Tube Extrusion ◽  
Deformation Parameters ◽  
Flow Features ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

By using Deform-3D software, the necking extrusion forming processes of integer trailer axle with two different heating means which are Uniform Heating (UH) method and Partly Heating (PH) method with temperature gradient are simulated. The influence of deformation parameters such as friction factor, necking coefficient, different temperature distribution of work-piece on the material flow features, stress and strain field, loading force and deformation process are analyzed in detail. According to the numerical simulation results, using PH method with temperature gradient can improve necking deformation during tube extrusion process.

Simulation of Compound Cold Extrusion Al-Zn-Mg-Cu Alumium Alloys

2012 ◽  
Vol 159 ◽  
pp. 257-261
Author(s):  
Zhi Ming Zhou ◽  
Wei Jiu Huang ◽  
Zhen Zhao ◽  
Bin Bin Lei ◽  
Chun Liu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Automotive Industry ◽  
Maximum Stress ◽  
Effective Strain ◽  
High Strength ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Processing Route ◽  
Deep Hole ◽  
Deform 3D

Al-Zn-Mg-Cu super-high strength aluminum alloy is widely used in the aerospace and automotive industry. However, the extrudability of Al-Zn-Mg-Cu aluminum alloy is relatively poor compared with other series of aluminum alloys. The simulation of compound cold extrusion process of Al-Zn-Mg-Cu aluminum alloy was studied for the production of a double-cup workpiece with a deep wobbler hole in this paper. The effective strain and stress distribution of the alloy during cold extrusion were studied by Deform-3D simulation. The results show that the maximum stress was concentrated at the bottom of the deep hole. Cracks were easily to be occured near the bottom of deep-hole. Based on the experimental results, the processing route of the two steps with compound cold extrusion is more suitable than one cold extrusion for the production.

Cold Extrusion Process Analysis of "Seven-Speed Sleeve" and Forming Parameter Optimization

2011 ◽  
Vol 199-200 ◽  
pp. 1924-1927
Author(s):  
Rong Xia Chai ◽  
Chen Guo ◽  
Hong Qi Hu ◽  
Li Yu Zhang
Keyword(s):  
Process Parameters ◽  
Process Analysis ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Extrusion Speed ◽  
Entrance Angle ◽  
Production Practice ◽  
Die Structure ◽  
3D Software ◽  
Deform 3D

The scheme for cold extrusion process of Seven-speed sleeve is determined according to the experiences and analysis by DEFORM-3D software, the extrusion procedure has been numerical simulation analyzed; The part technology and parameters of die structure has been optimized by orthogonal test. The optimized process parameters are as following: friction factor is 0.10, blank height is 31.4mm, extrusion speed is 200mm/s; The optimized parameters of die structure are as following: 1st step convex fillet is 1.5mm, 1st step concave rounded is 2.0mm, 2nd step convex fillet is 2.0mm, 2nd step concave rounded is 1.0mm, 1st step die-entrance angle is 35°, 2nd step die-entrance angle is 60°.The qualified products are obtained using the optimized process parameters in the production practice.

Simulation on Flexible Thixo-Extrusion of Variable Cross-Section Part Based on DEFORM-3D Software

2014 ◽  
Vol 217-218 ◽  
pp. 201-207
Author(s):  
Chun Fang Wang ◽  
Kai Kun Wang ◽  
Zhe Luo
Keyword(s):  
Aluminum Alloy ◽  
Control Method ◽  
Complex Geometry ◽  
Variable Cross Section ◽  
Extrusion Process ◽  
Simulation Software ◽  
Variable Cross ◽  
Stress Strain ◽  
Different Temperatures ◽  
Deform 3D

Flexible thixo-extrusion, as an innovative near-net-shape forming method, has huge advantages in processing the components with complex geometry. However, it should keep in mind that conventional liquid casting still represents the dominant mean of aluminum alloys production. One of the obstacles the thixo-extrusion has to overcome is lack of proof that can live up to the claim that thixo-extruded components have better mechanical properties. The main aim of this paper is to simulate the flexible thixo-extrusion process of aluminum alloy A356 and investigate the control method of materials flow front. An isothermal compression test of aluminum alloy A356 is first conducted to obtain the true stress-strain curves at different temperatures and strain rates. A constitutive equation describing the relationship of stress, strain, strain rate and temperature is fitted by Origin and then imported to the DEFORM-3D simulation software. The results show that the quality of final component is enormously influenced by the radius of the arcs and the flexible thixo-extruded components has less defects compared with the conventional extruded ones.

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

scholarly journals Analysis of deformation and microstructure evolution during the cogging process of Waspaloy alloy

2019 ◽  
Vol 254 ◽  
pp. 02008
Author(s):  
Marcin Kukuryk ◽  
Jerzy Winczek ◽  
Marek Gucwa
Keyword(s):  
Dynamic Recrystallization ◽  
Effective Strain ◽  
Three Dimensional ◽  
Work Piece ◽  
Commercial Program ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Evolution Of Microstructure ◽  
Deform 3D ◽  
Good Agreement

The hot deformation behavior of Waspaloy alloy has been investigated by two-pass hot cogging process. The paper presents theoretical end experimental analysis of deformations and microstructural evolutions. The results of a thermo-mechanical simulation for the spatial hot cogging process on the shaped anvils with the application of the three–dimensional finite element method, are presented. The numerical calculation gave an assessment of the effective strain, mean stress and temperature distributions in the work-piece. Models for predicting the evolution of microstructure were developed for dynamic recrystallization and grain growth phenomena. The influence of shape of the anvils on the grain size after dynamic recrystallization was analyzed. The numerical analysis was performed using a commercial program "DEFORM 3D" with thermo-mechanical and microstructural evolution coupled. The results are compared with the experimental data, a good agreement between the predicted and experimental results was obtained.

Computer simulation of the technology for AK4-1 alloy die forging production for an internal combustion engine piston

2020 ◽  
pp. 24-31
Author(s):  
I. L. Konstantinov ◽  
P. G. Potapov ◽  
S. B. Sidelnikov ◽  
D. S. Voroshilov ◽  
Yu. V. Gorokhov ◽  
...  
Keyword(s):  
Computer Simulation ◽  
Aluminum Alloy ◽  
Internal Combustion Engine ◽  
Combustion Engine ◽  
Internal Combustion ◽  
Die Forging ◽  
Real Process ◽  
3D Software ◽  
Hot Die Forging ◽  
Deform 3D

The process of hot die forging of AK4-1 aluminum alloy billets for the piston of an internal combustion engine (ICE) for an unmanned aerial vehicle (UAV) was simulated using the Deform-3D software package. The object of research was an ICE piston mounted on one of the UAV types of Russian production. Simulation was performed using the following parameters: tooling and billet temperature was 450 °C, ambient temperature was 20 °C, punch speed was 5 mm/s, and Siebel friction index was 0.4. Rigid plastic medium was chosen as a material model. The number of elements (6000) was selected so that at least 3 elements fit in the narrowest section of the part. Thus, as illustrated by the piston die forging, computer simulation in the Deform-3D software makes it possible to develop hot die forging processes for making aluminum alloy billets for UAV ICE pistons. At the same time, computer simulation can be used to evaluate the power parameters of the hot die forging process, study the nature of billet forming in die forging, make necessary adjustments to the virtual process, and develop the design of a die forging tool in order to select the most effective process solutions when designing a real process. The described computer simulation technique can be extended to other aluminum alloy die forgings.

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