scholarly journals A Special Extrusion-shear Manufacturing Method for Magnesium Alloy Rods Based on Finite Element Numerical Simulation and Experimental Verification

2022 ◽  
Author(s):  
Ou Zhang ◽  
Hongjun Hu ◽  
Huiling Zhang ◽  
Hui Zhao ◽  
Ding-fei Zhang ◽  
...  
Keyword(s):  
Magnesium Alloy ◽  
Metal Flow ◽  
Temperature Fields ◽  
Extrusion Speed ◽  
Manufacturing Method ◽  
Grain Sizes ◽  
Friction Factors ◽  
Finite Element Numerical Simulation ◽  
3D Software ◽  
Deform 3D

Abstract To research the influences of process parameters on a special extrusion-shearmanufacture method for magnesium alloy rods, deform-3d software with finite elementsimulations has been used to analyze the material flows of deformed magnesium alloysAZ31B during the extrusion-shear (ES) process, as well as the grain sizes anddistribution of extrusion loads, stresses and strains, and blank temperatures. Temperaturefields, stress fields, strain fields and temperature fields varying with different blankpreheating temperatures, extrusion speed and extrusion ratios were simulated. Influences ofdifferent extrusion conditions and different die structures on microstructures of rods prepared by ES process has been researched. Extrusion forces decrease with the increasing extrusion temperatures, decreasing extrusion ratios, increasing die channel angles and decreasing friction coefficients. The flow velocities of metal in the ES die increase with development of ES process. Increasing the channel angles and reducing the friction factors would increase the outflow velocities of metal, but it has little effect on the uniformity of metal flow. The increase in friction and extrusion speed would increase the temperatures of the ES die. The ES process can prepare finer and more uniform microstructures than those prepared by direct extrusion under the same conditions.

Influence of Friction on Metal Flow Behaviour and Die Stress of Backward Extrusion

2011 ◽  
Vol 117-119 ◽  
pp. 1719-1722
Author(s):  
Yong Shun Yang ◽  
Tian Tian Yin ◽  
Ke Feng
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Extrusion Process ◽  
Flow Behaviour ◽  
Backward Extrusion ◽  
Die Stress ◽  
3D Software ◽  
Deformation Area ◽  
Deform 3D ◽  
Unit Pressure

In the paper, the Deform-3D software was used to simulate the mechanism of metal flow behaviour under the influence of different friction in the backward extrusion process, and further study its influence on die stress. The numerical simulation demonstrates that: smaller friction could reduce difficult deformation area of extrusion metal significantly; friction state not only affected the plastic deformation extent, but also would increase the consumption of extrusion energy; the unit pressure of punch and stress of inner wall increased along with the increase of friction, meanwhile, the ratio of them increased as well.

The Quality Improvement in Manufacturing “Screw”-Parts Using the DEFORM-3D Software

2016 ◽  
Vol 684 ◽  
pp. 468-472 ◽  
Author(s):  
Sergey Zvonov ◽  
Aleksey Shlyapugin
Keyword(s):  
Aluminum Alloy ◽  
Quality Improvement ◽  
High Speed ◽  
Strain State ◽  
High Efficiency ◽  
Metal Flow ◽  
Stress Strain ◽  
Stress Strain State ◽  
3D Software ◽  
Deform 3D

The check of developed inventory for high-speed stamping "Screw"-part forging fabricated from aluminum alloy by using DEFORM is performed. The high efficiency of the program is shown. The characteristic of metal flow and stress-strain state during the processing is opened.

Effects of Friction on Precision Forging Process of Blade with a Damper Platform

2007 ◽  
Vol 561-565 ◽  
pp. 831-834 ◽  
Author(s):  
Yu Li Liu ◽  
He Yang ◽  
Tao Gao
Keyword(s):  
High Efficiency ◽  
Metal Flow ◽  
Vibration Characteristic ◽  
Technological Parameters ◽  
Forging Process ◽  
Precision Forging ◽  
Blade Forging ◽  
Deformation Defects ◽  
3D Software ◽  
Deform 3D

A blade with a damper platform, with excellent anti-vibration characteristic and high efficiency, has become one of the most important types of blades being developed in the aeronautical engines. During the precision forging process of this blade, the friction between dies and workpiece has important effects on metal flow, deformation defects, load and energy etc. So researching the effects of friction conditions on the forging process of blade with a damper platform has been a crucial problem urgent to be resolved. In this paper, the precision forging process of titanium alloy blade with a damper platform under different friction conditions has been simulated and analyzed based on the DEFORM-3D software platform. The obtained results reveal the influence laws of friction on temperature field and load-stroke curves, and provide a significant basis for determining technological parameters of the blade forging process.

The Cutting Simulation of Inconel 718

2010 ◽  
Vol 43 ◽  
pp. 717-721 ◽  
Author(s):  
Jia Long Ren ◽  
Qing Yu Zheng ◽  
Ren He ◽  
Chun Yan Zhang
Keyword(s):  
Heat Transfer ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Optimal Combination ◽  
Cutting Depth ◽  
Nickel Based Superalloy ◽  
Friction Factors ◽  
3D Software ◽  
Cooling And Lubrication ◽  
Deform 3D

The chemical composition and properties of nickel-based superalloy Inconel 718 was investigated first. Turning Inconel 718 was simulated by Deform-3D software to figure out main affection factors, and optimal combination of cutting speed, feed rate and cutting depth was introduced. In addition, different cooling and Lubrication methods (heat transfer coefficient f of cooling and tool-chip friction factors) for cutting of Inconel 718 was studied, and a best cooling/lub mode was obtained.

Simulation of Cold Extrusion Process of Hollow Pieces

2013 ◽  
Vol 446-447 ◽  
pp. 270-274
Author(s):  
Jia Long Ren ◽  
Xiao Xia Chen ◽  
Chun Yan Zhang ◽  
Xiao Fei Liu
Keyword(s):  
Strain Field ◽  
Cone Angle ◽  
Metal Flow ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Metal Deformation ◽  
3D Software ◽  
The Impact ◽  
Deform 3D ◽  
Virtual Velocity

The impact of friction factor, thickness of the cold extrusion, semi-cone angle and other factors on cold extrusion was analyzed. Various process parameters were set and optimized. Cold extrusion process of hollow pieces was simulated by DEFORM-3D software. Through the simulation of the virtual velocity field, strain field, stress field, load - stroke curve and metal deformation process, the flow velocity of the metal and the deformation of the workpiece were studied. The metal flow routes and the parts that are easy to wear in die were gained. The above research results provide valuable references for the processing of hollow pieces.

scholarly journals Experimental Research Regarding the Plastic Flow of Aluminium Alloy EN AW-7075 in Closed-die Forging Without Flash

2017 ◽  
Vol 54 (2) ◽  
pp. 326-330
Author(s):  
Maria Kapustova ◽  
Jozef Bilik ◽  
Martin Sahul ◽  
Martin Ridzon ◽  
Cristina Stefana Miron Borzan
Keyword(s):  
Plastic Flow ◽  
Point Of View ◽  
Economic Point ◽  
Manufacturing Method ◽  
Innovative Method ◽  
Die Forging ◽  
Closed Die Forging ◽  
Method Of Production ◽  
3D Software ◽  
Deform 3D

The paper describes an innovative method of production of non-ferrous drop forgings, a manufacturing method based on closed die forging without flash. From economic point of view, this method is very interesting for production, due to small quantity of lost material. The research was verified using DEFORM 3D software. In this way can be better understood the principles of forging process and can be analyzed the plastic flow of the material into the die cavity. This experiment was successfully performed at laboratory conditions and the results will be applied in practice.

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.

Analysis on Cupping Process of Cartridge Case without Heat Teatment Based on DEFORM-3D

2014 ◽  
Vol 912-914 ◽  
pp. 573-576 ◽  
Author(s):  
Jing Zhao ◽  
Zhong Hua Du ◽  
Jin Ku Zhao
Keyword(s):  
Heat Treatment ◽  
Research Method ◽  
Production Cost ◽  
Metal Flow ◽  
Forming Process ◽  
Increase Productivity ◽  
Simulation Results ◽  
Cartridge Case ◽  
3D Software ◽  
Deform 3D

To reduce the forming process of cartridge case, increase productivity and reduce production cost, this paper has analysed whether heat treatment is needed after cupping process of cartridge case by using DEFORM-3D software. Through comparing numerical simulation results of forming cartridge case after cupping process without heat treatment and with heat treatment, we obtain that large differences exist between them in forming effect and metal flow liquidity. Therefore, its inadvisable for cartridge case to go on the next process without heat treatment directly. The research method of this paper can effectively simulate the forming process of cartridge case. The improvement proposed for cartridge case forming can become a novel idea, and it also can provide a reference for future researchers.

Numerical Simulation of Extrusion of Hollow Profiles from Mg-Li Alloy

2015 ◽  
Vol 641 ◽  
pp. 210-217
Author(s):  
W. Libura ◽  
Artur Rękas ◽  
Mateusz Milczanowski ◽  
Katarzyna Milczanowska
Keyword(s):  
Numerical Simulation ◽  
Magnesium Alloys ◽  
Metal Flow ◽  
Aviation Industry ◽  
Stress And Strain ◽  
Optimal Temperature ◽  
Die Geometry ◽  
3D Software ◽  
Lithium Alloys ◽  
Deform 3D

Magnesium is the lightest metal used for construction elements. Due to their lightness and good mechanical properties magnesium alloys have been used in aviation industry since 50’s of the last century. Magnesium – Lithium alloys are the lightest of all magnesium alloys. Their density can be lower than 1,0 g/cm3. In this paper the results of numerical simulation of direct extrusion of Mg-Li alloy hollow profile are presented. The alloy has 12% addition of Lithium and has been extruded through porthole dies. The analysis of temperature distribution, metal flow and stress and strain with the use of Finite Element Method (FEM) have been calculated in Deform 3D software. The mathematical simulation have been performed for various ingot temperatures and the die’s geometry. Thanks to numerical simulation, the optimal temperature and die geometry have been determined and due to this fact the optimal stress conditions in a welding chamber have been obtained

scholarly journals Influences of Expanding Angles on Extrusion-Shearing-Expansion Processing of AZ31 Magnesium Alloy Thin-Walled Tubes

2021 ◽  
Author(s):  
Ye TIAN ◽  
Hong jun HU ◽  
Pengcheng LIANG ◽  
Dingfei ZHANG ◽  
Zhongwen OU
Keyword(s):  
Mechanical Properties ◽  
Magnesium Alloy ◽  
Extrusion Direction ◽  
Optical Microscope ◽  
Az31 Magnesium Alloy ◽  
Expansion Process ◽  
X Ray ◽  
Grain Sizes ◽  
Thin Walled ◽  
Deform 3D

Abstract To research the influence mechanisms of expanding angles on extrusion-shearing-expansion(ESE) process of AZ31 magnesium alloy thin-walled tubes,the effects of different expanding angles on microstructures and mechanical properties of AZ31 magnesium alloy during extrusion-shear-expansion process have been investigated by optical microscope(OM),scanning electron microscope (SEM),X-ray diffractometer(XRD).Three expanding angles 130°,140°,150° have been used.The forming loads varying with expanding ratios,and equivalent strains at various expanding angles have been simulated by Deform-3D software.The research results show that the qualities and mechanical properties of the formed tube are satisfactory, and extrusion-shearing-expanding process can refine the grain of AZ31 magnesium alloy thin-walled tubes.The grain sizes decrease with the decrease of expanding angles.When the expanding angle is 140°,the comprehensive mechanical properties are best,and yield strength is 122.3MPa,the tensile strength 288.6MPa,the elongation 15.2%, the texture intense is optimized due to the DRX.The deflections of basal plane for most grains are obvious relative to the extrusion direction(ED).

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