Selection of Optimal Hot Extrusion Process Parameters for AA6061-Fly Ash Composites

2018 ◽  
Vol 5 (1) ◽  
pp. 52-67 ◽  
Author(s):  
Sarojini Jajimoggala
Keyword(s):  
Process Parameters ◽  
Process Development ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Billet Temperature ◽  
Temperature Changes ◽  
H13 Tool Steel ◽  
Half Angle ◽  
Ram Speed ◽  
Simulation Parameters

The simulation of hot extrusion process is a challenging problem in process modeling because of very large deformations, strain rates and temperature changes during the process. The process development in industrial extrusion is to a maximum extent based on trial and error and often involves full size experiments. Numerical simulations can replace most of these experiments, which are often both time consuming and expensive. Hence in the present work, attempt has been made to simulate hot extrusion process. AA6061-flyash Metal Matrix Composite(MMC) as billet, H13 tool steel as the die, 400oC as billet temperature and extrusion ratio of 25:4 are used as simulation parameters. Simulation is performed using software DEFORM 3D by varying ram speed, Cone Half Angle (CHA) and friction coefficient with extrusion load. The effects of change of process parameters were observed and optimal process parameters were selected.

FEM Simulation of the Whole Circle of Aluminum Hot Extrusion Using Circular Dies With Different Extrusion Angle

2006 ◽  
Author(s):  
A. Lontos ◽  
K.-D. Bouzakis ◽  
G. Demosthenous ◽  
A. Baldoukas
Keyword(s):  
Product Quality ◽  
Process Parameters ◽  
Surface Condition ◽  
Fem Simulation ◽  
Hot Extrusion ◽  
Die Design ◽  
Work Piece ◽  
Billet Temperature ◽  
Extrusion Die ◽  
Ram Speed

On of the most typical forming processes used for the production of long, straight semi-finished products in the form of various section geometries is extrusion. Hot extrusion is a thermo-mechanical process whish involves complicated interactions between process parameters, tooling and deforming material /1,2/. In the present paper, FEM simulation is performed in the aluminum extrusion using circular dies with different geometries in order to extract quantitative simulating results regarding various forming parameters. Most specifically the parameters that are investigated are the die design-geometry, the process parameters (i.e. ram speed, container temperature, billet temperature) and the product quality (i.e. extruded shape, surface condition). The finite element modeling is based on 3D simulation tools using the DEFORM 3D software /3–5/. The used work piece is the aluminum AA6061 in cylindrical form with a diameter of 14 mm. The used material for the extrusion die is the hot work steel AISI H13. The geometry of the die is circular with a variation in die angle. The container and the billet temperature will vary from 450 to 550 degrees, and the mandrel (ram) speed will be at the range of 2 mm/sec. On the basis of simulating results such as pressure distribution on the extrusion die, effective stresses on the billet and product quality, new and improve die geometry will be introduced. Although the simulation problem is an axisymmetric one the authors decide to proceed with 3D FEM simulation in order to examine and verify the 3D simulating results. This paper is the first part of a further research project in which more complicated die geometries will be used as simulating and experimental specimens. In addition to simulating results, experimental results will be presented in the next few months.

Quantitative Study on the Effect of Extrusion Process of AZ80 Magnesium Alloy

2010 ◽  
Vol 129-131 ◽  
pp. 1191-1195
Author(s):  
Yan Lou
Keyword(s):  
Set Theory ◽  
Rough Set ◽  
Rough Set Theory ◽  
Extrusion Process ◽  
Average Weight ◽  
Characteristic Parameters ◽  
Billet Temperature ◽  
Az80 Magnesium Alloy ◽  
Ram Speed

By data mining from 3DFEM simulation and Rough Set Theory (RST), it was performed that the extrusion process and die structures effect on the quality of AZ80 magnesium extrudate. The weights of the effect can be obtained. The results show that the effect of the billet temperature on the product quality is dominate, and its average weight is 0.27. The second important parameter is the ram speed and its average weight is 0.22. In addition, it was also found that the effect of the die characteristic parameters on the extrudate is insignificant.

Study of Flow Balance and Temperature Evolution over Multiple Aluminum Extrusion Press Cycles with HyperXtrude 9.0

2009 ◽  
Vol 424 ◽  
pp. 257-264 ◽  
Author(s):  
Amin Farjad Bastani ◽  
Trond Aukrust ◽  
Inge Skauvik
Keyword(s):  
Finite Element ◽  
Finite Elements ◽  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Billet Temperature ◽  
Exit Velocity ◽  
Extrusion Press ◽  
Flow Balance ◽  
Exit Temperature ◽  
Ram Speed

In this research, transient finite element simulations of the aluminum extrusion process have been performed in order to study how process parameters influence flow balance and exit temperature. This has been achieved by investigating the influence of billet taper, front billet temperature and ram speed on the run-out velocity and temperature of two separate outlets. Analysis of variance (ANOVA) has been employed to study the effect of each parameter on the velocity and temperature variation of the extruded section. Results show that increasing each of these three parameters results in an undesired increase in exit velocity and temperature. The front billet temperature is found to be the most significant factor affecting the variation. The finite elements software used was Altair HyperXtrude 9.0.

Simulation of the Grain Structure Evolution of a Mg-Al-Ca-Based Alloy during Hot Extrusion Using the Cellular Automation Method

2011 ◽  
Vol 491 ◽  
pp. 265-272 ◽  
Author(s):  
L. Li ◽  
F. He ◽  
X. Liu ◽  
Yan Lou ◽  
Jie Zhou ◽  
...  
Keyword(s):  
Hot Extrusion ◽  
Extrusion Process ◽  
Grain Structure ◽  
Structure Evolution ◽  
Compression Tests ◽  
3D Fem ◽  
Parameter Recovery ◽  
Cellular Automation ◽  
Average Grain Size ◽  
Ram Speed

In the present study, the evolution of the grain structure of a Mg-Al-Ca-based alloy during hot extrusion was simulated with the cellular automation method. The Laasraoui-Jonas microstructure model was used to describe the dislocation evolution inside crystallites during dynamic recrystallization. The parameters in the Laasraoui-Jonas model, such as the hardening parameter, recovery parameter and material constants, were determined from the flow stress-strain data obtained from hot compression tests using a Gleeble-1500 thermomechanical simulator. The extrusion process was simulated using a DEFORM 3D FEM code. The influence of ram speed on grain structure evolution was analyzed. It was found that the average grain size increases with increasing ram speed. Good agreements between the predicted and observed grain structures were achieved.

Quantitative Analysis of the Extrusion Process of AZ31 Magnesium Alloy Based on Rough Set Theory and 3DFEM Simulation

2010 ◽  
Vol 455 ◽  
pp. 200-205 ◽  
Author(s):  
Yan Lou
Keyword(s):  
Product Quality ◽  
Set Theory ◽  
Rough Set ◽  
Rough Set Theory ◽  
Processing Parameters ◽  
Extrusion Process ◽  
Die Design ◽  
Average Weight ◽  
Billet Temperature ◽  
Ram Speed

The effect of extrusion process on the quality of AZ31 magnesium extrudate was performed, by data mining from 3DFEM simulation and Rough Set Theory(RST). The weight of the effect of processing parameters and die structures can be obtained to predict the product quality, to optimize the extrusion processing and the die design. The results show that the effect of the billet temperature on the product quality is dominate, and its average weight is 0.25. The second important parameter is the ram speed and its average weight is 0.21. The third is the extrusion ratio. Its average weight is 0.18. In addition, it was also found that the effect of the die characteristic parameters on the extrudate is insignificant. Finally, the rationality of the weight of effect was verified through experiments.

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.

Contrasting Models to Determine the Approximate Extrusion Process Conditions for the First Billet

2009 ◽  
Vol 424 ◽  
pp. 249-256
Author(s):  
Marc Sabater ◽  
Maria Luisa García-Romeu
Keyword(s):  
Neural Networks ◽  
Process Parameters ◽  
Extrusion Process ◽  
Predictor Variables ◽  
Process Conditions ◽  
Extrusion Speed ◽  
Billet Temperature ◽  
Regression Techniques

This paper is focused on determining extrusion process conditions for the first billet and, particularly, on selecting an adequate billet temperature and extrusion speed. It is important to predict these values before adjusting the die to avoid lengthy and unproductive preparation times, and to make die adjustment easier during the tests. With that in mind, this study employs two models to determine the first billet temperature (TFB) and the extrusion speed (SE) parameters: one that applies regression techniques and another that uses neural networks. The aim of this paper is to present the results obtained by comparing the performance of the two models to determine which one offers the best results. We also analyze whether changing the number of patterns for construction of the models will improve results. The models are based on extrusion process parameters taken from real industry contexts. The results indicate that the variables chosen as predictor variables for the extrusion speed output must be refined.

The Investigation of Hot Extrusion Process Parameters on Microstructure and Mechanical Performance of Aluminium Alloy in Biomedical Industry

2021 ◽  
pp. 327-332
Author(s):  
Nor Fadhilah Mohamad Khalili ◽  
Hoo Jian Jun ◽  
Azlan Ahmad ◽  
Nabihah Sallih ◽  
Mohd Amri Lajis ◽  
...  
Keyword(s):  
Aluminium Alloy ◽  
Process Parameters ◽  
Mechanical Performance ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Biomedical Industry

Analyses of Plastic Flow and Die Design during Hot Extrusion of Magnesium Alloy Strips

2010 ◽  
Vol 443 ◽  
pp. 98-103 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Shih Ming Tu
Keyword(s):  
Magnesium Alloy ◽  
Plastic Flow ◽  
Thickness Distribution ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
Thin Strip ◽  
Compression Tests ◽  
Ram Speed ◽  
Product Thickness

This study involves analyses and experiments of hot extrusion of magnesium alloy strips. Hot compression tests were firstly conducted to obtain the magnesium alloy’s plastic flow stresses at high temperatures. These data are used in the finite element simulations of the thin strip extrusion process. Using the FE simulations, the flow pattern of the magnesium alloy billet within the die, the temperature variation and the thickness distribution at the die exit were analyzed. The effects of different die bearing height design, initial billet temperatures and ram speed on the extrusion load, the temperature at the die exit and the product thickness distribution were also discussed. Finally, hot extrusion experiments were conducted and the experimental values of the extrusion load and dimensions of the products were compared with the analytical values to validate the analytical model. Sound products were obtained using the best designed bearing heights and other appropriate extrusion conditions.

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