Simulation of Compound Cold Extrusion Al-Zn-Mg-Cu Alumium Alloys

2012 ◽  
Vol 159 ◽  
pp. 257-261
Author(s):  
Zhi Ming Zhou ◽  
Wei Jiu Huang ◽  
Zhen Zhao ◽  
Bin Bin Lei ◽  
Chun Liu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Automotive Industry ◽  
Maximum Stress ◽  
Effective Strain ◽  
High Strength ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Processing Route ◽  
Deep Hole ◽  
Deform 3D

Al-Zn-Mg-Cu super-high strength aluminum alloy is widely used in the aerospace and automotive industry. However, the extrudability of Al-Zn-Mg-Cu aluminum alloy is relatively poor compared with other series of aluminum alloys. The simulation of compound cold extrusion process of Al-Zn-Mg-Cu aluminum alloy was studied for the production of a double-cup workpiece with a deep wobbler hole in this paper. The effective strain and stress distribution of the alloy during cold extrusion were studied by Deform-3D simulation. The results show that the maximum stress was concentrated at the bottom of the deep hole. Cracks were easily to be occured near the bottom of deep-hole. Based on the experimental results, the processing route of the two steps with compound cold extrusion is more suitable than one cold extrusion for the production.

Effect of Process Parameters on the Microstructure Homogeneity of AA6082 Aluminum Alloy Deformed by Twist Extrusion

2013 ◽  
Author(s):  
V. S. Senthil Kumar ◽  
U. Mohammed Iqbal
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Effective Strain ◽  
Extrusion Process ◽  
Work Piece ◽  
Hardness Testing ◽  
Twist Extrusion ◽  
Experimental Values ◽  
3D Software ◽  
Deform 3D

Twist extrusion is a severe plastic deformation in which the rectangular shaped work piece is extruded through a die with a twist channel. In this work the twist extrusion process of AA6082 T6 aluminum samples were carried out to investigate the effects of process parameters like temperature and deformation passes on the microstructure homogeneity. The results indicate that the grain refinement of AA 6082 T6 aluminum alloy leads to inhomogeneous microstructure after one twist extrusion pass. On further extrusion passes the inhomogeneity in the microstructure is found to be disappeared. The homogeneity of the distribution of the deformation was confirmed by micro hardness testing. Finite element modeling has been performed in DEFORM 3D software for determining the homogeneity of the effective strain distribution which agreed well with the experimental values.

Simulation on Flexible Thixo-Extrusion of Variable Cross-Section Part Based on DEFORM-3D Software

2014 ◽  
Vol 217-218 ◽  
pp. 201-207
Author(s):  
Chun Fang Wang ◽  
Kai Kun Wang ◽  
Zhe Luo
Keyword(s):  
Aluminum Alloy ◽  
Control Method ◽  
Complex Geometry ◽  
Variable Cross Section ◽  
Extrusion Process ◽  
Simulation Software ◽  
Variable Cross ◽  
Stress Strain ◽  
Different Temperatures ◽  
Deform 3D

Flexible thixo-extrusion, as an innovative near-net-shape forming method, has huge advantages in processing the components with complex geometry. However, it should keep in mind that conventional liquid casting still represents the dominant mean of aluminum alloys production. One of the obstacles the thixo-extrusion has to overcome is lack of proof that can live up to the claim that thixo-extruded components have better mechanical properties. The main aim of this paper is to simulate the flexible thixo-extrusion process of aluminum alloy A356 and investigate the control method of materials flow front. An isothermal compression test of aluminum alloy A356 is first conducted to obtain the true stress-strain curves at different temperatures and strain rates. A constitutive equation describing the relationship of stress, strain, strain rate and temperature is fitted by Origin and then imported to the DEFORM-3D simulation software. The results show that the quality of final component is enormously influenced by the radius of the arcs and the flexible thixo-extruded components has less defects compared with the conventional extruded ones.

Solid Welding Conditions for Seam and Hollow Extrusion Process of 7075 Aluminum Alloy

2011 ◽  
Vol 479 ◽  
pp. 62-73 ◽  
Author(s):  
Quang Cherng Hsu ◽  
Kun Hong Kuo ◽  
Chi Peng Hsu
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Cross Sections ◽  
High Strength ◽  
Extrusion Process ◽  
Protective Atmosphere ◽  
Porthole Die ◽  
Die Structure ◽  
Welding Strength ◽  
Good Agreement

Direct extrusion by porthole – bridge die configuration has been successfully used to fabricate products with hollow cross sections for 6000 series aluminum alloys. However, if for 7000 series aluminum alloys, this situation alerts since different alloy composition such as Cu causing hollow extrusion failed due to not enough welding strength in seam. In order to determine the solid welding conditions during hollow extrusion with porthole die structure for high strength aluminum alloy, an easy tooling configuration has been designed. The proposed method is easy and cheap because there is no necessary to conduct experiment in controlled environment such as in vacuum chamber of Gleeble test or in a protective atmosphere. A seam and hollow extrusion for square tube has been conducted to obtain the welding strength comparison to the proposed solid welding method which shows good agreement.

Press Forging Forming of Stepped Holes in Thick Sheet Metal

2013 ◽  
Vol 706-708 ◽  
pp. 234-237
Author(s):  
Xu Jun Cao ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Chong Chao Lin
Keyword(s):  
Sheet Metal ◽  
Effective Strain ◽  
Extrusion Process ◽  
Thick Sheet ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thick Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

Press forging forming of thick sheet metal is a combined extrusion process, which is put forward in the presently study. A new technological scheme for a two-step press forging of stepped holes in a thick metal sheet was proposed. Finite element analysis on the two-step process is carried out by using DEFORM-3D. Distributions of effective strain and effective stress were obtained. The study showed that the process not only can form the stepped holes, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulations process parameter, an experimental die was designed, the simulation results were in good agreement with the experimental data.

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.

Plastic Deformation Simulation on Compound Twist Extrusion Process for Metal Materials

2013 ◽  
Vol 291-294 ◽  
pp. 2676-2679 ◽  
Author(s):  
Yong Zhi Li ◽  
Xue Fei Du
Keyword(s):  
Plastic Deformation ◽  
Severe Plastic Deformation ◽  
Effective Strain ◽  
Extrusion Process ◽  
Ultrafine Grained ◽  
Twist Extrusion ◽  
The Subject ◽  
Intensive Investigation ◽  
3D Software ◽  
Deform 3D

Severe plastic deformation（SPD）methods have been the subject of intensive investigation for preparing bulk ultrafine-grained materials in recent years. This paper introduces a new severe plastic deformation (SPD) process named as C-TE process which combines the Twist Extrusion with Extrusion against the asymmetric deformation of TE process. and the distribution of effective strain and stress of the sample and the variation of load with time and its influence on the deformation were investigated by computer simulation with Deform-3D software . The results reveal that C-TE process can significantly slow uniform phenomenon,and a sample of homogeneous deformation can be obtained by the improved process.

Numerical Analysis of Rolling Extrusion Process of a Hollow Hub / Analiza Numeryczna Procesu Przepychania Obrotowego Piasty Drążonej

2012 ◽  
Vol 57 (4) ◽  
pp. 1137-1142 ◽  
Author(s):  
J. Bartnicki
Keyword(s):  
Numerical Analysis ◽  
Effective Stress ◽  
Experimental Verification ◽  
Effective Strain ◽  
Metal Flow ◽  
Three Dimensional ◽  
Extrusion Process ◽  
Design Tools ◽  
Extruded Product ◽  
Deform 3D

This paper presents the results of numerical calculations of rolling extrusion process of a hollow hub. Simulations were made by means of software Deform 3D in three dimensional state of strain. Distributions of effective stress, effective strain and damage criterion in the rolled extruded product were analyzed. Verification of metal flow during process allowed to design tools for experimental verification in PO-2 laboratory rolling - extrusion aggregate. For these needs also process force parameters were calculated.

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.

scholarly journals Force and pressure function formulation for direct cold extrusion of aluminum alloy Al 1350 using regression method

2021 ◽  
pp. 38-43
Author(s):  
Fadi Alfaqs ◽  
Ghazi S Marahleh
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Extrusion Process ◽  
Regression Method ◽  
Cold Extrusion ◽  
Extrusion Force ◽  
Mathematical Tool ◽  
Extrusion Dies ◽  
Mathematical Formulas

Purpose. Establishing methodology in order to determine mathematically both extrusion force and pressure functions for Aluminum alloy AL 1350 using the regression method of experimental data. Methodology. Several variables (diameter of the cavity for pressing D, degree of extrusion, angle of the punch head cone 2, and ratio of the semi-finished sizes Rs) were included when using the regression method considered. Findings. Diameter and strain were found to play a significant role in predicting both extrusion force and pressure functions associated with the extrusion process. Mathematical formulas for force and pressure were obtained using the regression method. Amethodology has been developed for the mathematical determination of extrusion force and pressure. Originality. Force and pressure functions in direct cold extrusion process are mainly required for the design of extrusion dies. However, the existence of such data in the literature is insufficient to implement the process for direct cold extrusion of aluminum and aluminum alloys as well as for other materials. Results of the study consider the main factors influencing extrusion force and pressure as well as the main differences for types of aluminum alloys. Practical value. The mathematical formulas obtained by the regression method provide a mathematical tool for calculating force and pressure values in direct extrusion process.

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