Mechanical Failure Study of Aluminum Extrusion Dies as Affected by the Quality of the Billets

2014 ◽  
Vol 42 (4) ◽  
pp. 20120291
Author(s):  
Shadi Al Khateeb ◽  
Amin Al robaidi ◽  
Radwan Dweiri ◽  
Ahmad Lebzo ◽  
Mahmood Al-Sawa'adeh
Keyword(s):  
Mechanical Failure ◽  
Aluminum Extrusion ◽  
Extrusion Dies

Increased Productivity in Hot Aluminum Extrusion by Using Extrusion Dies with Inner Cooling Channels Manufactured by Rapid Tooling

2014 ◽  
Vol 611-612 ◽  
pp. 981-988 ◽  
Author(s):  
Ramona Hölker ◽  
Matthias Haase ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Surface Defects ◽  
Experimental Investigations ◽  
Extrusion Force ◽  
Aluminum Extrusion ◽  
Thermally Induced ◽  
Manufacturing Method ◽  
Cooling Channels ◽  
Extrusion Dies ◽  
Exit Temperature ◽  
Tooling Technology

The influence of local inner die cooling on the heat balance in hot aluminum extrusion was investigated. For the manufacturing of the die with cooling channels close to the forming zone, the layer-laminated manufacturing method was applied. The new tooling technology was applied in order to decrease the profiles exit temperature and to avoid thermally induced surface defects with the aim to raise the productivity in hot aluminum extrusion processes. Numerical and experimental investigations revealed that, while maintaining the exit temperature of the extrudate, a distinct increase of the production speed up to 300% can be realized, while the extrusion force increases only slightly. An effect on the profiles microstructure was also detected. By applying die cooling, grain coarsening can be significantly limited or even be avoided.

New Concepts for Cooling of Extrusion Dies Manufactured by Rapid Tooling

2011 ◽  
Vol 491 ◽  
pp. 223-232 ◽  
Author(s):  
Ramona Hölker ◽  
Andreas Jäger ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Rapid Tooling ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Workpiece Material ◽  
Cooling Channels ◽  
Extrusion Dies ◽  
Local Overheating ◽  
New Concepts ◽  
Die Surface ◽  
Manufacturing Technologies

To prevent local overheating of the workpiece material in hot aluminum extrusion the influence of die cooling was investigated. Numerical simulations of extrusion revealed an advantage of the die bearing cooling, which can be accomplished by locating the cooling channels close to the die/bearing surface. Since the fabrication of especially geometric complex cooling channels located near the die surface is not possible by conventional manufacturing technologies, the technology of rapid tooling was introduced into hot aluminum extrusion and experimentally tested. Cooling channels near to the bearings show promising results allowing extensions of extrusion limits, especially the extrusion speed and therefore productivity.

Microstructure and Mechanical Properties of FSWed Aluminum Extrusion with Bobbin Tools

2012 ◽  
Vol 706-709 ◽  
pp. 990-995 ◽  
Author(s):  
K. Okamoto ◽  
A. Sato ◽  
Seung Hwan C. Park ◽  
Satoshi Hirano
Keyword(s):  
Mechanical Properties ◽  
Feed Rate ◽  
Rotation Speed ◽  
Tool Design ◽  
Aluminum Extrusion ◽  
Tool Rotation Speed ◽  
Process Robustness ◽  
Tool Rotation ◽  
Process Productivity

Bobbin FSW technique is assessed in terms of process productivity and robustness considering the metallurgical and mechanical qualities of the joint. Several different designed bobbin tools were applied to aluminium A6xxx alloy extrusions, at feed rate of 400-1000mm/min with tool rotation speed of 600-1000rpm. In case of A6068-T6, a joint efficiency of 68% was achieved at 600mm/min, which is almost equivalent to the productivity and quality of the conventional FSWed joints, hence the potential of bobbin FSW technique was suggested. The bobbin tool design was further optimized considering the practical process robustness to the part fit issue, and defect free welds have been achieved for the joints with a set gap up to 1mm. However, the oxide remnant, so called “lazy S” was observed in a joint made with an inadequate designed tool, which significantly deteriorates the mechanical properties.

Extrusion Benchmark 2013 - Experimental Analysis of Mandrel Deflection, Local Temperature and Pressure in Extrusion Dies

2013 ◽  
Vol 585 ◽  
pp. 13-22 ◽  
Author(s):  
Alessandro Selvaggio ◽  
Thomas Kloppenborg ◽  
Martin Schwane ◽  
Ramona Hölker ◽  
Andreas Jäger ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Experimental Investigations ◽  
Measurement Equipment ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Statistical Validation ◽  
Extrusion Dies ◽  
Special Measurement ◽  
Die Temperature ◽  
Temperature And Pressure

A bridge die was designed for the simultaneous extrusion of two rectangular profiles and used in a strictly monitored aluminum extrusion process. Experimental investigations aimed at the measurement of the mandrel deflection, the local die temperature, and the pressure inside the welding chamber by means of special measurement equipment. AA6082 alloy was used as extrusion material. The influence of the extrusion speed on the aforementioned objectives is reported. The experiments were repeated at least three times under the same conditions in order to achieve a statistical validation of the acquired data. These data are provided as reference for the 2013 edition of the Extrusion Benchmark.

VISCOUNT 20

Alloy Digest ◽  
1985 ◽  
Vol 34 (9) ◽  
Keyword(s):  
Physical Properties ◽  
Heat Treating ◽  
Aluminum Extrusion ◽  
Steel Company ◽  
Extrusion Dies ◽  
Hot Work Steel ◽  
Selection For

Abstract VISCOUNT 20 is an air-hardening, 5% chromium hot-work steel with the same analysis as Latrobe's VDC except for the addition of carefully controlled and evenly dispersed alloy sulfides. These additives improve the machinability of the steel so that it is an excellent selection for a variety of hot-work applications where machinability is of primary importance. Its many uses include forging and heading dies, aluminum extrusion dies, mandrels and mold dies for plastics. This datasheet provides information on composition, physical properties, hardness, and elasticity. It also includes information on heat treating and machining. Filing Code: TS-446. Producer or source: Latrobe Steel Company.

Heat treatment of aluminum extrusion dies and study of their heating by convection/radiation

2014 ◽  
Vol 78 (1-4) ◽  
pp. 419-430 ◽  
Author(s):  
Miguel Oliveira ◽  
António Duarte ◽  
Paulo Coelho ◽  
José Marafona
Keyword(s):  
Heat Treatment ◽  
Aluminum Extrusion ◽  
Extrusion Dies

scholarly journals Effect of Pocket Height on Aluminum flow through zero-bearing extrusion dies to produce single solid profile using FEM Simulation: تأثير ارتفاع المغذي على تدفق الألمنيوم عبر قوالب البثق ذات سطح الضبط الصفري لإنتاج مقطع مصمت مفرد بطريقة العناصر المنتهية

2020 ◽  
Vol 4 (4) ◽  
Author(s):  
Mohammad Majed Altaleb, Almohannad Makki
Keyword(s):  
Fem Simulation ◽  
Practical Experience ◽  
Aluminum Extrusion ◽  
Forming Process ◽  
Rectangular Section ◽  
Cross Sectional ◽  
Extrusion Dies ◽  
Flow Through ◽  
Feeder Design ◽  
Relative Flow

Extrusion is known as an industrial forming process for producing long sections with a fixed cross-sectional area and is often used to extrude colored metals, especially aluminum. The aluminum rods (Billets) are heated and pressed through a die to obtain the required profile. The research aims to study the effect of Pocket height when using zero bearing dies by modeling using the INSPIRE EXTRUDE METAL program package for a single rectangular section of 65 mm in length and 1.5 mm in width, and then to conduct experimental verification of the results by designing, manufacturing and testing a real mold in an aluminum extrusion factory that matches one of the molds Studied. As we studied a group of molds that have a Pocket so that the height of the pocket in them changes from zero (a reference flat die) to a height of 20 mm. The feeder design takes into account the homogenization of the flow across the studied section, which narrows in the center and widens at the edges. The measurement of the relative flow velocity at the front of the section was used as an indicator to analyze the results of the analytical experiment. The study showed that a certain height of the feeder of 10 mm must be maintained for the studied section. The FEM results and the practical experience were identical. This shows the importance of the FEM and its effectiveness in shortening the experimental work and that it can, to a large extent, save time and effort to manufacture, test and correct dies.

scholarly journals A New Cone-Friction Test for Evaluating Friction Phenomena in Extrusion Processes

2009 ◽  
Vol 424 ◽  
pp. 161-166 ◽  
Author(s):  
C. Karadogan ◽  
R. Grueebler ◽  
Pavel Hora
Keyword(s):  
Physical Modeling ◽  
Flow Distribution ◽  
Experimental Setup ◽  
Aluminum Extrusion ◽  
Friction Test ◽  
Extrusion Dies ◽  
Influential Parameters

Friction is one of the most influential parameters in extrusion processes. The flow distribution is controlled using the effect of friction lengths on the extrusion dies. A comparison between multi-hole die aluminum extrusion experiments and simulations [1] necessitated studies on numerical and physical modeling of friction during aluminum extrusion. In order to measure the friction under conditions similar to extrusion processes a new experimental setup is proposed.

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