scholarly journals Numerical Simulation and Process Optimization of Internal Thread Cold Extrusion Process

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 3960
Author(s):  
Hong-Ling Hou ◽  
Guang-Peng Zhang ◽  
Chen Xin ◽  
Yong-Qiang Zhao
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Extrusion Process ◽  
Extrusion Temperature ◽  
Maximum Temperature ◽  
Cold Extrusion ◽  
Internal Thread ◽  
Bottom Hole ◽  
Extrusion Forming

In the internal thread extrusion forming, if the process parameters are not selected properly, the extrusion torque will increase, the extrusion temperature will be too high, or even the tap will break. In order to obtain effective process parameters under certain working conditions, this paper uses a combination of numerical simulation and process experiment to analyze the influence of the bottom hole diameter, extrusion speed, and friction factor on the extrusion torque and extrusion temperature. Through an orthogonal experiment, the significant influence law of different process parameters on the extrusion torque and extrusion temperature was studied, and the order of their influence was determined. Based on the optimal process parameters, numerical simulations and process tests were carried out, and the extrusion effect and related parameters were compared and analyzed. The results show that the extruded thread has clear contour, uniform tooth pitch, complete tooth shape, and good flatness. Compared with before optimization, the maximum extrusion torque has been reduced by 37.15%, the maximum temperature has been reduced by 29.72%, and the extrusion quality has been improved. It shows that the optimized method and optimized process parameters have good engineering practicability.

scholarly journals The Influence of the Bottom Hole of Cold Extruding Internal Thread on Thread Quality

Mechanika ◽  
2021 ◽  
Vol 27 (4) ◽  
pp. 335-341
Author(s):  
Hongling Hou ◽  
Xin CHEN ◽  
Yongqiang ZHAO ◽  
Yayin HE ◽  
Changqian WANG
Keyword(s):  
Numerical Simulation ◽  
Extrusion Process ◽  
High Rate ◽  
Cold Extrusion ◽  
Internal Thread ◽  
Important Indicator ◽  
Good Surface ◽  
Bottom Hole ◽  
Simulation Results ◽  
The Relationship

The diameter of the threaded bottom hole determines whether the extrusion can proceed smoothly and the fullness of the tooth shape after extrusion. The tooth height rate is an important indicator of the strength of the threaded connection. In order to establish the relationship between the diameter of the bottom hole and the tooth height of the extruded internal thread, this paper takes the aluminum alloy M8×1.25 mm internal thread as an example, and uses a method of combining numerical simulation and process test. Obtained the changing law of internal thread profile and tooth height rate of extruded workpieces with different bottom hole diameters. Using MATLAB to fit the numerical simulation results, the relationship between the tooth height of the internal thread and the diameter of the prefabricated bottom hole of the workpiece was obtained. The reliability of the numerical simulation results and the feasibility of the fitting formula are verified through experiments. The results show that the diameter of the prefabricated bottom hole of the workpiece is controlled within 7.33~7.39 mm when the M8×1.25 mm internal thread is processed by the cold extrusion process. The high rate of the internal thread after extrusion meets the requirements of thread connection strength, and the internal thread has high forming quality and good surface quality.

Numerical Simulation Research on Springback Controlling Methods of Aluminum Alloy Panel during Hydroforming

2016 ◽  
Vol 851 ◽  
pp. 163-167
Author(s):  
Dong Yan Lin ◽  
Yi Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Blank Holder Force ◽  
Scoring Method ◽  
Simulation Research ◽  
Blank Holder ◽  
Hydroforming Process

The hydroforming process of the aluminum alloy panel was simulated by the software DYNAFORM. The effects of process parameters (blank holder force, depth of panel and height of draw bead) on springback of the aluminum alloy were investigated. The max springback of the panel was analyzed by weighted scoring method. Then the process parameters were synthetically optimized for the max positive and negative springback. The results showed that the height of draw bead affects obviously the comprehensive springback of the panel. The optimization of the process parameters obtained by the orthogonal experiment can effectively reduce the max springback of the panel.

scholarly journals Numerical Simulation of Moving Heat Flux during Selective Laser Melting of AlSi25 Alloy Powder

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 877
Author(s):  
Cong Ma ◽  
Xianshun Wei ◽  
Biao Yan ◽  
Pengfei Yan
Keyword(s):  
Numerical Simulation ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Molten Pool ◽  
Laser Power ◽  
Scanning Speed ◽  
Powder Layer ◽  
Maximum Temperature ◽  
Three Dimensional Model ◽  
Laser Melting

A single-layer three-dimensional model was created to simulate multi-channel scanning of AlSi25 powder in selective laser melting (SLM) by the finite element method. Thermal behaviors of laser power and scanning speed in the procedure of SLM AlSi25 powder were studied. With the increase of laser power, the maximum temperature, size and cooling rate of the molten pool increase, while the scanning speed decreases. For an expected SLM process, a perfect molten pool can be generated using process parameters of laser power of 180 W and a scanning speed of 200 mm/s. The pool is greater than the width of the scanning interval, the depth of the molten pool is close to scan powder layer thickness, the temperature of the molten pool is higher than the melting point temperature of the powder and the parameters of the width and depth are the highest. To confirm the accuracy of the simulation results of forecasting excellent process parameters, the SLM experiment of forming AlSi25 powder was carried out. The surface morphology of the printed sample is intact without holes and defects, and a satisfactory metallurgical bond between adjacent scanning channels and adjacent scanning layers was achieved. Therefore, the development of numerical simulation in this paper provides an effective method to obtain the best process parameters, which can be used as a choice to further improve SLM process parameters. In the future, metallographic technology can also be implemented to obtain the width-to-depth ratio of the SLM sample molten pool, enhancing the connection between experiment and theory.

scholarly journals Effect of Forming Parameters on Profile Thinning of Flexible 3D Multi-Point Stretch Bending

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1581
Author(s):  
Zhongyuan Shi ◽  
Yi Li ◽  
Jicai Liang ◽  
Ce Liang
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Three Dimensional ◽  
Simulation Software ◽  
Experimental Result ◽  
Range Analysis ◽  
Stretch Bending ◽  
Rectangular Profile ◽  
Aluminum Profiles

The ABAQUS finite element simulation software is used to simulate the flexible multi-point three-dimensional stretch bending process of aluminum profiles. The effect of process parameters on the web thickness of rectangular profile in flexible multi-point three-dimensional stretch bending is studied by orthogonal experiment and range analysis. The process parameters used in the experiments include pre-stretching value, post-stretching value, the number of multi-point dies and friction coefficient. The optimal combination of process parameters is obtained by numerical simulation and experimental verification. When the aluminum profile is completed flexible multi-point stretch bending according to the best parameters, the thickness thinning of outer web and inner web is the smallest. The experimental result is closed to the numerical simulated results. The effectiveness of the numerical simulation is verified by the corresponding experimental methods.

Numerical Analysis on the Density Uniformity for SiCp/2024Al in the Extrusion Process

2016 ◽  
Vol 850 ◽  
pp. 536-543 ◽  
Author(s):  
Yan Ju Wang ◽  
De Sheng Chu ◽  
Peng Jun Tang ◽  
Yong Jun Guan
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Physical Simulation ◽  
Influence Factors ◽  
Fem Simulation ◽  
Aluminum Matrix ◽  
Strain Curve ◽  
Extrusion Process ◽  
Aluminum Matrix Composites ◽  
Matrix Composites

Many factors can influence the density uniformity of the SiC particle reinforced aluminum matrix composites, including the material preparation method and the material processing technology. The influence factors on the density uniformity of SiCp/2024Al in the extrusion process were studied in the present investigation. Those factors contain the extrusion ratio, the extrusion velocity, the temperature and the friction coefficient. The flow stress of this material under different temperatures and strain velocities was tested by heat physical simulation experiments. As a result, the true stress-strain curve was obtained and the phenomenological constitutive equation was established, and the FEM simulation was used for the extrusion process. The velocity gradient computed by the numerical simulation was used to describe the density uniformity. The density uniformity caused by different extrusion process parameters was compared and analyzed. The results showed that the density uniformity was improved obviously by the optimization of extrusion process parameters. At last, the real extrusion process test was organized to verify the numerical simulation results and the most suitable characteristic parameters of the extrusion mold and the process was finally determined.

Multi-Scale Numerical Simulation of H62 Brass for Hot-Extrusion Process

2010 ◽  
Vol 97-101 ◽  
pp. 2880-2885
Author(s):  
Yan Hong Xiao ◽  
Chen Guo ◽  
Xiao Kang Tian
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
High Temperature Deformation ◽  
Temperature Deformation ◽  
Influence Of Process Parameters ◽  
Multi Scale ◽  
Microstructure Prediction ◽  
Sine Functions

Thermal deformation process of H62 brass is studied, multi-scale simulations of macro-forming property and microstructure distribution are carried out for the hot-extrusion process of double cups part with flange utilizing numerical simulation technology, the process parameters are determined and the microstructure of extruded parts is predicted. The constitutive equation of H62 brass under high temperature deformation is established with isothermal compression test, and the results indicate that the flow stress accords to Arrhenius hyperbolic sine functions. The model of microstructure evolution during hot-deformation is founded and the influence of process parameters on microstructure is revealed. The microstructure prediction on extruded part shows that the simulated results agree well with the experimental results. The high-quality products are obtained using the optimal process parameters.

Research on the Decision Support System for Cold Extrusion Process of Internal Thread

2016 ◽  
Vol 693 ◽  
pp. 1867-1879
Author(s):  
Hong Miao ◽  
Qing Mei ◽  
Jing Yun Yuan ◽  
Zai Xiang Zheng ◽  
Yi Fu Jin ◽  
...  
Keyword(s):  
Decision Support ◽  
Decision Support System ◽  
Support System ◽  
Three Dimensional ◽  
Extrusion Process ◽  
Frame Structure ◽  
Cold Extrusion ◽  
Internal Thread ◽  
Related Information ◽  
Application Requirements

This paper established the model base, knowledge base, application base and test base for the cold extrusion process of internal thread and developed decision support system which realized the centralized management of related information for cold extrusion process of internal thread, maintained the consistency of data in real time and enforced the degree of information sharing. By using of the decision support system, expert system, intelligent inference technology and depending on the application requirements of the system, the overall structure of the decision support system for cold extrusion process of internal thread was established based on J2EE technology. Two accessorial decision-making methods of hybrid forecasting and application modification facilitated modeling the system business. Three-dimensional frame structure was used to represent the application example of the internal thread by cold extrusion process and to achieve the application type, information scalability of internal thread by cold extrusion process. Hybrid fast predicting mechanism which was the dynamic integration of internal thread by cold extrusion process knowledge and instance inference was applied to seek the optimal degree of internal thread by cold extrusion process.

Deform Based 1Cr18Ni9Ti Pipe Joint Upsetting Extrusion Process Finite Element Numerical Simulation Analysis

2013 ◽  
Vol 365-366 ◽  
pp. 1128-1131
Author(s):  
Zhi Yi Huo ◽  
Ying Zhi Li ◽  
Xiu Qian Sun ◽  
Qian Wang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Simulation Analysis ◽  
Extrusion Process ◽  
Forming Process ◽  
Element Analysis ◽  
Part Quality ◽  
Quantitative Basis ◽  
Extrusion Forming ◽  
Pipe Joint

Internal Defects are more likely to occur when 1Cr18Ni9Ti pipe joint are produced by traditional casting method or welding forming method, while the upsetting extrusion proposed in this essay can not only meet the part quality requirements, but also save material and shorten processing cycle. By numerical simulation analysis about part upsetting extrusion forming process with the finite element analysis method, we can obtain many index numerical values in part forming process, and therefore provide reliable quantitative basis for optimum design.

Numerical Simulation for Cold Extrusion of Bevel Gear

2012 ◽  
Vol 497 ◽  
pp. 356-364
Author(s):  
Qing Hua Yang ◽  
Jun Pan ◽  
Jun Xiong Zhang ◽  
Wen Biao Chen ◽  
Bin Meng
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Bevel Gear ◽  
Basic Knowledge ◽  
Cold Extrusion ◽  
Forming Process ◽  
Load Curve ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

A three-layers assembled cavity die and its technological measures were designed for cold extrusion forming for the bevel gear. Numerical simulation of the cold extrusion forming process was applied using Deform-3D software, load curve, velocity field, stress field and temperature field were analyzed, thus obtain the basic knowledge of the law of the bevel gear deformation. Subsequent targets for optimization were introduced, aiming to solve the remaining problems of the current cold extrusion forming. The accomplished work shows some significance in guiding how to design a die and its technological measures.

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.

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