Temperature Evolution and Optimization of Hot Extrusion Process for Al-Zn-Mg-Cu Aluminium Alloy Based on FEM Simulation

2012 ◽  
Vol 166-169 ◽  
pp. 896-901
Author(s):  
Lei Xu ◽  
Guang Ze Dai ◽  
Xing Min Huang ◽  
Jun Wen Zhao ◽  
Jing Han ◽  
...  
Keyword(s):  
Stress State ◽  
Fem Simulation ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Maximum Temperature ◽  
Tension Stress ◽  
Incipient Melting ◽  
Extrusion Speed ◽  
Cu Alloy ◽  
The Right

Hot extrusion process of Al-Zn-Mg-Cu alloy billet had been simulated under different temperature of billet and container. It was proposed that due to large deformation and friction, maximum temperature of the billet occurs on the skin near extrusion export and is under three direction tension stress state, where surface is likely to crack if temperature surpassed the incipient melting point. The right temperature of the billet and container is 425°C~450°C and 400°C respectively with the constant extrusion speed 0.8mm/s

Application of Appropriate Coatings on Extrusion Dies and Evaluation of Their Performance During Hot Extrusion of Aluminum

2010 ◽  
Author(s):  
Antonios Lontos ◽  
George Demosthenous ◽  
Filippos Soukatzidis
Keyword(s):  
Hot Extrusion ◽  
Experimental Tests ◽  
Working Life ◽  
Element Model ◽  
Extrusion Process ◽  
Extrusion Speed ◽  
Coating Materials ◽  
Extrusion Dies ◽  
Billet Material ◽  
Aluminum Material

The aim of this paper is to study the effect of extrusion parameters (extrusion speed and temperature), die geometry, and the application of appropriate coating materials on the extrusion dies in order to extend their working life. To achieve the above goal FEM techniques and experimental tests adopted and simulating and experimental results evaluated. In this way, special FEM software was used to set up the finite element model of the aluminum extrusion. As a billet material the 6061 aluminum was used, with a specific diameter and length. The extrusion process was modeled as isothermal, which means that the billet material preheated at the specific temperature and then it was pressured into the two different dies, with a specific extrusion ratio. The extrusion speed was varied between 0.5 to 1 mm/sec and the extrusion temperature varied between 400 °C to 500 °C. The extrusion angle of the two different dies was 9° degrees. The fillet radius at the top surfaces was selected to be 1 mm. The friction between aluminum material (billet) and the extrusion equipment was i) aluminum material and die 0.3, ii) aluminum material and ram 0.9 and iii) aluminum material and container equal to 0.96. Optimized algorithms of extrusion parameters were proposed regarding to the concluded simulating results. The results obtain from the simulation procedure help to the better understanding of the specific extrusion process, leading to better modification of the experimental procedure. In this way, experimental tests were conducted on special laboratory extrusion press using the two different die geometries coated with three different PVD coatings. By means of these experimental tests the additional working life of the coated dies, during hot extrusion process, was able to be evaluated. In addition, the three different coatings where tested by established quality procedures in order to determine their behavior on the material of the extrusion die.

Experimental and Numerical Analysis of the Friction Condition in the Die Bearing during Aluminum Extrusion

2011 ◽  
Vol 491 ◽  
pp. 113-119 ◽  
Author(s):  
Sören Müller ◽  
Jerome Muehlhause ◽  
J. Maier ◽  
Pavel Hora
Keyword(s):  
Fem Simulation ◽  
Extrusion Process ◽  
Friction Model ◽  
Friction Condition ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Die Geometry ◽  
Various Boundary Conditions ◽  
Strain And Strain Rate ◽  
Realistic Representation

Of the various boundary conditions that are relevant for the correct modeling of the extrusion process the realistic representation of the friction in the die is important since it has a significant influence on the profile temperature, the strain and strain rate distribution in the die. In order to investigate the influence of the die geometry, respectively the geometry of the die bearing, a four-hole die with exchangeable inserts was designed. Thereby each of the four inserts was equipped with a thermocouple to record the profile temperature at the die bearing. Through the combination of different die bearing geometries (cylindrical, 0.5° closing, 1° closing, 0.5° opening) in the same die the influence on the extrusion speed and profile temperature could be evaluated with the exact same extrusion conditions. The observed differences in the temperature and speed in respect to the geometry of the die bearing where evaluated and implemented in a FEM simulation in order to validate the underlying friction model.

Numerical Simulation of Canned Hot-Extrusion Process of Mo Powder

2011 ◽  
Vol 295-297 ◽  
pp. 1341-1346
Author(s):  
Jian Li ◽  
Jun Zhang
Keyword(s):  
Equivalent Stress ◽  
Hot Extrusion ◽  
Material Model ◽  
Extrusion Process ◽  
Equivalent Strain ◽  
Maximum Temperature ◽  
Entrance Angle ◽  
Finite Element Software ◽  
The Press ◽  
Maximum Equivalent Stress

Aiming at the stress state in the hot-extrusion process of Mo powder, the paper has studied the 3D stress characteristics provided by the hot-extrusion of the canning. The material model is established by the finite element software DEFORM-3D. Via calculating, the load-stroke curve, temperature, relative density, the equivalent stress and the equivalent strain distribution characteristics were obtained. The results show that canned powder after hot-extrusion technology can improve its density greatly. The press load grows fleetly at early, and then slowly grows at the stable stage. Only reach last stage the press load drops quickly of the hot-extrusion. The maximum temperature and maximum equivalent strain appear below the die entrance. The maximum equivalent stress appears in the die entrance. Therefore ,the die entrance angle and the surface geometric parameters of the die have significant effects on the equivalent stress.

Investigation and Comparison of Heat Transfers Analysis Used in Commercial FEM for Metal Forming

2013 ◽  
Vol 773-774 ◽  
pp. 176-185
Author(s):  
Isaac Flitta ◽  
Thomas Hatzenbichler ◽  
Bruno Buchmayr
Keyword(s):  
Heat Transfer ◽  
Fem Simulation ◽  
Tool Material ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Material Interface ◽  
Transfer Parameter ◽  
Aluminium Extrusion ◽  
Definition Of ◽  
Heat Transfer Parameter

During an Aluminium extrusion process, the extrusion parameters, i.e. friction, heat transfer, etc. are significantly influence by the temperature gradients produced in the billet during transfer to the container and after upsetting the container. The heat transfer at the tool/billet interface governs the temperature profile throughout the billet and tools during extrusion and consequently has a critical influence on the results. Although FEM technique offers great potential, care must be taken when applying the analysis to the hot extrusion of rate sensitive alloys. The most useful approach of an FEM simulation would thus be to include both the tooling and the billet in the calculation as discretised meshes. Because of the occurrence of the conductive and convective heat transfer, the deformation during hot extrusion is not adiabatic and estimation of the temperature increase is alloy dependent. The aim of this paper is to investigate and to compare how commercial FEM codes assign and deal with the heat transfer parameter at the tool/material interface. Three commercial FEM codes were investigated and compared; Simufact, Deform and Forge. The usefulness and limitation when using commercial FEM codes are discussed. Methods to assess difficulty of comparison are presented. The work illustrates the essentials of numerical analysis in the comprehension of the thermo-mechanical events occurring during large deformation. Results are presented for velocity distribution and temperature evolution in both materials and tools. It is shown that the heat transfer parameter to be extremely sensitive when attempting to simulate the hot deformation. Moreover, the accuracy of the results does not only depended on the geometric definition of the tooling and material data but also the governing boundary conditions between the material and tooling.

Correlation of Nonuniformities of the Seebeck Coefficient’s Distribution and the Strain-Stress State in Extruded Thermoelectric Material

2019 ◽  
Vol 822 ◽  
pp. 291-297
Author(s):  
Arseniy A. Rulimov ◽  
Daria D. Kuzavkova ◽  
Sergey A. Nemov ◽  
Alexandr Maksimovich Zolotov
Keyword(s):  
Stress State ◽  
Seebeck Coefficient ◽  
Thermoelectric Material ◽  
Software Package ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Molding Machine ◽  
Accumulated Strain ◽  
Strain Stress ◽  
P Type

In this work, p-type thermoelectric material was produced by hot extrusion of pre-synthesized in injection molding machine Bi0.5Sb1.5Te3 solid solution. During the research radial distribution of the Seebeck coefficient was confirmed and described in material’s cross section using thermal measuring probe. Such nonuniformity of the Seebeck coefficient is correlated with the strain-stress state of extrudate specifically with the distribution of accumulated strain intensity, which was obtained by mathematical modeling of extrusion process using the software package DEFORM.

Investigation of the Mandrel’s Stress States and Wear Conditions during Tube Hot Extrusion of IN690 Superalloy

2014 ◽  
Vol 622-623 ◽  
pp. 111-118
Author(s):  
Jing Yang ◽  
Qing Jun Zhou ◽  
Chao Yang Sun ◽  
Dong Liu
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Hot Extrusion ◽  
Element Model ◽  
Extrusion Process ◽  
Wear Model ◽  
Extrusion Speed ◽  
Preheating Temperature ◽  
Stress States ◽  
Symmetric Finite Element

A 2D axi-symmetric finite element model for tube hot extrusion process has been established by consideration of the billet transfer, glass lubrication, constitutive equation of IN690 superalloy and modified Archard wear model. The influence of extrusion process parameters on the stress state and wear conditions of the mandrel surface has been investigated. The results show that under the optimal extrusion process parameters of the extrusion speed of 250 mm/s, the friction factor of 0.05 and the billet preheating temperature of 1250 ̊C, the mandrel can be reused 200 times when it is fixed and 500 times when it moves with the ram.

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

2-D viscoelastic FEM simulation on stress state in the deep part of a subducted slab

2002 ◽  
Vol 15 (3) ◽  
pp. 301-308 ◽  
Author(s):  
Ya-jing Liu ◽  
Guo-yang Ye ◽  
Xing-hua Mao ◽  
Jie-yuan Ning
Keyword(s):  
Stress State ◽  
Fem Simulation ◽  
Deep Part

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.

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.

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