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.

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 Die Design for Extrusion Process of Titanium Seamless Tube Using Finite Element Analysis

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1338
Author(s):  
Byung-Jin Choi ◽  
In Yong Moon ◽  
Young-Seok Oh ◽  
Seong-Hoon Kang ◽  
Se-Jong Kim ◽  
...  
Keyword(s):  
Finite Element ◽  
Extrusion Process ◽  
Maximum Principal Stress ◽  
Die Design ◽  
Von Mises Stress ◽  
Design Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Corner Radius ◽  
Von Mises

In this paper, the extrusion process of titanium seamless tubes was studied using several finite element (FE) analyses. First, the finite element result was compared with experimental extrusion data acquired to validate the current analysis. Then, the effect of design parameters of the die shape was numerically analyzed using commercial FE software, Forge NxT, for the metal forming process. Elastic FE analyses were also conducted for dies to analyze the maximum principal stress that affects the early fracture of dies during the extrusion process and the maximum von Mises stress that causes the severe deformation of dies. Consequently, the effect of the corner radius at the exit and land length on the extrusion load and die stress is negligible compared to that of the corner radius at the entrance and die angle. Finally, we suggested a die angle of 60° and a corner radius at the die entrance between 10 and 15 mm as an optimal design for the current extrusion process.

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.

A new upper bound solution for the analysis of the twist extrusion process with an elliptical die cross-section

2009 ◽  
Vol 223 (9) ◽  
pp. 1975-1981 ◽  
Author(s):  
Salehi M Seyed ◽  
S Serajzadeh
Keyword(s):  
Upper Bound ◽  
Extrusion Process ◽  
Die Design ◽  
Design Parameters ◽  
Element Analysis ◽  
Die Geometry ◽  
Proposed Model ◽  
Twist Extrusion ◽  
Upper Bound Technique ◽  
Highly Strained

The twist extrusion process is a rather new route to produce highly strained materials. In this process, severe plastic deformation is applied by large shear strains. In this regard, prediction of materials behaviour and extrusion pressure is of importance to die designers and engineers. In this article, utilizing an admissible velocity field together with the upper bound technique, the required energy for twist extrusion is predicted. The proposed model is capable of considering the effect of various parameters such as die geometry and friction conditions. In addition, the model anticipates the critical die design parameters. To verify the proposed model, the predictions are compared with the results of a finite-element analysis and reasonable consistency is observed.

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.

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.

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.

Studies on Process Parameters for Aluminum Extrusion of Slide Rails

2013 ◽  
Vol 467 ◽  
pp. 392-397 ◽  
Author(s):  
Shun Yu Shao ◽  
Wen Yen Wang ◽  
Yi An Chen
Keyword(s):  
Aluminum Alloy ◽  
Process Design ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Roll Forming ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Extrusion Die ◽  
Simulation Results ◽  
Product Weight

Slide rails are usually fabricated by roll forming and are used in kitchenware and cabinets mostly. However the product weight of slide rails is increased because larger dimensions are required to bear larger load when they are used in dies and warehouses. International suppliers start to develop Aluminum slide rails to decrease the product weight in recent years. The manufacturing and functional feasibility of Aluminum slide rail were discussed in this study. The Aluminum slide rail was designed according to ready-made slide rail, and the aluminum alloy was selected with required mechanical properties. The suitable extrusion die was designed and direct extrusion parameters of extrusion ratio, extrusion temperature, extrusion speed and extrusion load are also considered. The extrusion process of aluminum alloy was simulated by CAE software to check the mold and process design. The extrusion part of aluminum slide rail was carried out by extruder to verify the simulation results.

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