scholarly journals Simulation and Experiment of Manufacturing Process for Structural Aluminum Parts with Hard to Plastic Forming

Metals ◽  
2019 ◽  
Vol 9 (2) ◽  
pp. 207
Author(s):  
Chul Jin
Keyword(s):  
Extrusion Direction ◽  
Hot Extrusion ◽  
Maximum Load ◽  
Extrusion Process ◽  
Cylindrical Part ◽  
Forging Process ◽  
Plastic Forming ◽  
Forming Analysis ◽  
Simulation And Experiment ◽  
Warm Forging

A process comprising a hot extrusion process and a warm forging process was designed to form an umbrella-shaped aluminum structural component with a high degree of difficulty for the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, and then an embossing part was produced with a warm forging process. The formability and the maximum load required for forming were then determined using a forming analysis program. The hot extrusion process was executed at 450 °C under the extrusion speed at 6 mm/s, while the warm forging process was executed at 260 °C under the forging speed at 150 mm/s. The simulation results showed that the load required for hot extrusion was 1019 ton, while the load required for the warm forging was 534 ton. The umbrella-shaped part was manufactured by using a 1600 ton capacity press. The graphite lubricant was coated on the mold as well as the material. A forming experiment was performed under the same condition with the simulation condition. The portion where extrusion was done became elliptical with the α-Al phase elongated towards extrusion direction. Whereas, the α-Al phase became circular in the forged portion. The tensile strength value was found as 345 MPa, while elongation rate was 12%. Meanwhile, Vickers hardness value at the extruded portion was 105 HV, and it was 110 HV at the forged portion.

Effects of Microstructure and Texture on the Mechanical Properties of Extruded Mg−Gd−Nd−Y−Zn Alloy

2012 ◽  
Vol 509 ◽  
pp. 68-74
Author(s):  
Xiu Li Hou ◽  
Xu Sun ◽  
Li Min Wang ◽  
Zhan Yi Cao
Keyword(s):  
Mechanical Properties ◽  
Extrusion Direction ◽  
Aging Treatment ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Fiber Texture ◽  
Alloy Sheet ◽  
Mechanical Anisotropy ◽  
Aged Alloy ◽  
Zn Alloy

In present work, the Mg−Gd−Nd−Y−Zn alloy sheets were prepared by hot extrusion technique. The microstructure, texture and mechanical properties of the extruded alloy were investigated. After hot extrusion, the alloy reveals a greatly refined microstructure due to the dynamic recrystallization. The coarse eutectic phases were crushed into small particles during extrusion process, which brings a promotion of grain refinement. A weak basal fiber texture was obtained in the as-extruded alloy owing to the influence of RE (rare earth) alloying elements. The as-extruded alloy exhibits mechanical anisotropy that the strengths and elongations in the extrusion direction are both higher than those in the transverse direction. And this behavior does not change with increasing temperature. It results from the weak texture and the distribution of eutectic phase particles in the alloy sheet. Through isothermal aging treatment, significant strengthening is achieved in the peak-aged alloy, and the mechanical anisotropy still exists.

Deformation Behaviors of Non-Metallic Inclusion in FGH96 Superalloy during Different Plastic Processes

2012 ◽  
Vol 538-541 ◽  
pp. 1187-1191
Author(s):  
Min Cong Zhang ◽  
Chen Yi Liu ◽  
Shu Yun Wang
Keyword(s):  
Transition Zone ◽  
Extrusion Direction ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Metallic Inclusion ◽  
Isothermal Forging ◽  
Forging Process ◽  
Discontinuous Line ◽  
Metallic Inclusions ◽  
Deformation Behaviors

The non-metallic inclusions in FGH96 superalloy during different plastic processes were studied. The results show that SiO2 react with aluminum and titanium in FGH96 superalloy and the reaction zone is formed in the interface between SiO2 and alloy, whereas Al2O3 react with no elements in FGH96 superalloy and the transition zone between them is mechanical combination during the plastic processes. In addition the sizes of non-metallic inclusions increase in the direction perpendicular to deformation during isothermal forging process. The non-metallic inclusions are pulled into a discontinuous line in extrusion direction and areas of non-metallic inclusions in each direction are constricted during extrusion process. The non-metallic inclusions of FGH96 superalloy is conditioned by the state of the as-extrusion inclusions during extrusion+isothermal forging process. In summary, extrusion process with large extrusion ratio can break the non-metallic inclusions in FGH96 alloy effectively and improve forging quality.

In-Situ Solid-State Synthesis of Mg Composite with Mg2Si Dispersoids

2005 ◽  
Vol 475-479 ◽  
pp. 497-500
Author(s):  
Ritsuko Tsuzuki ◽  
Katsuyoshi Kondoh
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
High Performance ◽  
Extrusion Direction ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Synthesis Temperature ◽  
Solid State Synthesis ◽  
Casting Alloys

Super light and high performance Mg2Si/Mg composites, which had excellent mechanical properties, were developed via the combination of solid-state synthesis and hot extrusion process. In this study, cold compacting (CP) and repeated plastic working (RPW) were firstly carried out for the mixture of Mg-Si powders, and the refinement of both Mg grains and dispersoids. Each specimen was evaluated by observation of microstructure and tensile test. As a result, it was understood that Mg2Si dispersoids were refined and dispersed into Mg matrix, and were flowed along extrusion direction. And their mechanical properties were higher than the conventional die casting alloys. Also the effect of RPW as the improvement of properties and the decrease of synthesis temperature were confirmed.

Microstructure and Mechanical Properties of As-Cast and As-Extruded Mg-Gd-Er-Zn-Zr Alloy

2015 ◽  
Vol 1088 ◽  
pp. 221-226 ◽  
Author(s):  
Kai Wen ◽  
Wen Bo Du ◽  
Ke Liu ◽  
Zhao Hui Wang ◽  
Shu Bo Li
Keyword(s):  
Mechanical Properties ◽  
Tensile Test ◽  
Room Temperature ◽  
Cast Alloy ◽  
Extrusion Direction ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Microstructure And Mechanical Properties ◽  
Room Temperature Tensile Test ◽  
Zr Alloy

The Microstructure and mechanical properties of as-cast and as-extruded Mg-12Gd-2Er-1Zn-0.6Zr alloy are investigated in the present paper. The microstructure is analyzed by OM, SEM and TEM with SAED, and the mechanical properties are valued by the room temperature tensile test. The result shows that the coarse Mg5(Gd, Er, Zn) phase in the as-cast alloy was broken during hot extrusion process, and it was distributed at the grain boundary along the extrusion direction. The enhancement in mechanical properties of the extruded alloy is mainly ascribed to the refinement of these grains. The sizes of dynamical recrystallized grains are homogeneously, which was about 7 μm. Stacking fault existed in the as-cast alloy, which has a little effect on the dynamic recrystallization because of its tiny thicknesses.

Tool Design Induced Anisotropic Flow Behavior of Hot Extruded Aluminum Profiles

2013 ◽  
Vol 585 ◽  
pp. 131-138
Author(s):  
Stefan Ossenkemper ◽  
Matthias Haase ◽  
Celal Soyarslan ◽  
Andreas Jäger ◽  
A. Erman Tekkaya
Keyword(s):  
Flow Behavior ◽  
Extrusion Direction ◽  
Hot Extrusion ◽  
Longitudinal Direction ◽  
Extrusion Process ◽  
Tool Design ◽  
Compression Tests ◽  
Lateral Direction ◽  
Plane Anisotropy ◽  
Aluminum Profiles

The hot extrusion process may lead to frequently observed textures in the profiles, like fiber structures in longitudinal direction. Aluminum profiles (AA6060) were extruded with different tool types (flat-face dies and modified porthole dies). Compression tests of cylindrical specimens, which were machined out of these profiles likewise in extrusion direction, were conducted to examine possible effects of the in-plane anisotropy in lateral direction. A hardness distribution over the cross section of the specimens was measured. It was found that dependent on tool design and profile geometry, the specimens developed preferred lateral flow directions during upsetting. Simulations of the upsetting test, with assigned Hill parameters to consider anisotropy of the material, showed, that this anisotropy, not the local hardness nonuniformity, is the main reason for the detected plastic flow properties.

Analysis and optimization of hot extrusion process on strenx steel 900

2021 ◽  
Author(s):  
A. Damodar Reddy ◽  
P.N. Karthikeyan ◽  
S. Krishnaraj ◽  
Adarsh Ajayan ◽  
K. Sunil Kumar Reddy ◽  
...  
Keyword(s):  
Hot Extrusion ◽  
Extrusion Process

scholarly journals Friction-Induced Recycling Process for User-Specific Semi-Finished Product Production

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 663
Author(s):  
Thomas Borgert ◽  
Werner Homberg
Keyword(s):  
High Efficiency ◽  
Research Work ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Efficient Production ◽  
Secondary Aluminum ◽  
Shape Accuracy ◽  
Aluminum Chips ◽  
Spinning Process ◽  
Complex Parts

Modern forming processes often allow today the efficient production of complex parts. In order to increase the sustainability of forming processes it would be favorable if the forming of workpieces becomes possible using production waste. At the Chair of Forming and Machining Technology of the Paderborn University (LUF) research is presently conducted with the overall goal to produce workpieces directly from secondary aluminum (e.g., powder and chips). Therefore, friction-based forming processes like friction spinning (or cognate processes) are used due to their high efficiency. As a pre-step, the production of semi-finished parts was the subject of accorded research work at the LUF. Therefore, a friction-based hot extrusion process was used for the full recycling or rework of aluminum chips into profiles. Investigations of the recycled semi-finished products show that they are comparable to conventionally produced semi-finished products in terms of dimensional stability and shape accuracy. An analysis of the mechanical properties of hardness and tensile strength shows that a final product with good and homogeneously distributed properties can be produced. Furthermore, significant correlations to the friction spinning process could be found that are useful for the above-mentioned direct part production from secondary aluminum.

Extrusion Simulation and Texture Study on Mg-Y Alloy

2015 ◽  
Vol 817 ◽  
pp. 531-537 ◽  
Author(s):  
Tao Tang ◽  
Yi Chuan Shao ◽  
Da Yong Li ◽  
Ying Hong Peng
Keyword(s):  
Steady State ◽  
Texture Evolution ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Deformation Texture ◽  
Arbitrary Lagrangian Eulerian ◽  
Fe Method ◽  
Tracer Particles ◽  
Numerical Simulation Methods ◽  
Crystal Plasticity Theory

In order to study the influence of extrusion process on texture development of alloys, numerical simulation methods were used to simulate the round and shape extrusion process and deformation texture. Extrusion of Mg-Y magnesium alloy was carried out at the temperature of 673K with different ram speeds to verify the simulation results. Instead of using the Lagrangian FE method, the Arbitrary Lagrangian-Eulerian (ALE) method was employed in this study so that a more accurate description of the steady-state extrusion process can be achieved. By obtaining strain histories of specified material tracer particles, the coupling of deformation and crystal plasticity theory was applied to simulate the texture evolution in hot extrusion. The results showed that the texture simulation corresponded well with the experimental ones. The study proposes a method to analyze the steady-state extrusion process and texture evolution, and can be used as a useful tool in optimizing the extrusion process.

Structure, Texture and Mechanical Properties through the Section of the Hot-Extruded Tube of Titanium Alloy PT-1M

2020 ◽  
Vol 989 ◽  
pp. 139-144 ◽  
Author(s):  
F.V. Vodolazskiy ◽  
N.A. Barannikova ◽  
Anatoly G. Illarionov
Keyword(s):  
Titanium Alloy ◽  
Extrusion Direction ◽  
Hot Extrusion ◽  
Tangential Direction ◽  
Primary Recrystallization ◽  
Recrystallization Temperature ◽  
Fine Grained ◽  
Surface Areas ◽  
Α Phase ◽  
Fine Grained Structure

The study considers the formation of the structure, texture, and hardness of hot extruded tube of titanium alloy PT-1M. It is shown that hot extrusion at 840 °C, which is higher than the α-phase recrystallization temperature, results to the development of dynamic and primary recrystallization processes and ensures the formation of homogeneous and fine-grained structure through-out the cross section with a two-component tangential texture (0001)TD<100>ED+(0001)TD<110>ED (TD – tangential direction, ED – extrusion direction) and hardness of 155 HV. It has been established that a higher cooling rate of the surface areas of the tube after extrusion results to a less active development of recrystallization processes, which lead to the formation of a finer granular structure near the outer surface. This weakens recrystallization component of (0001)TD<110>ED, compared to other areas of the tube.

Research on Influence of Process Parameters on Sheet Metal Extrusion Force

2009 ◽  
Vol 16-19 ◽  
pp. 515-519
Author(s):  
Hua Xiang ◽  
Xin Cun Zhuang ◽  
Zhen Zhao
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Fem Simulation ◽  
Extrusion Process ◽  
Orthogonal Experimental Design ◽  
Extrusion Force ◽  
Influence Of Process Parameters ◽  
Tool Shape ◽  
Simulation And Experiment ◽  
Metal Extrusion

Extrusion force plays a significant role on sheet metal extrusion process. It is characterized by various process parameters including material properties, extrusion ratio, friction, tool shape etc. In this paper, a reasonable FEM model of sheet metal extrusion process was established and validated by comparing the results of simulation and experiment firstly. Based on the reliable model, the effect on extrusion force of various process parameters was investigated with orthogonal experimental design combined FEM simulation. The work presented in this paper has laid certain foundation for further work of modeling and optimizing extrusion force.

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