Numerical Simulation of Cold Extrusion Process of the ZA Alloy Car Sleeve Based on LS-DYNA

2013 ◽  
Vol 411-414 ◽  
pp. 3056-3059
Author(s):  
Zhi Qiang Li ◽  
Han Xun Lv ◽  
Bing Dong Liu ◽  
Zhang Yi Yu
Keyword(s):  
Equivalent Stress ◽  
Equivalent Plastic Strain ◽  
Processing Parameters ◽  
Extrusion Process ◽  
Raw Material ◽  
Cold Extrusion ◽  
Forming Process ◽  
Contrastive Study ◽  
Finite Element Technology ◽  
Extrusion Technology

In order to increase the useful life of sleeve, improve the organizational structure and reduce costs, ZA alloy materials can be used as a raw material using cold extrusion technology for production. The main content of this paper is simulating the change rules of the equivalent plastic strain, the equivalent stress and the flow in the forming process of ZA alloy in different extrusion speed and friction coefficient condition by finite element technology, making a contrastive study with the extrusion theory, and finding out the most appropriate extrusion processing parameters. The results not only provide sufficient theatrical support for the cold extrusion process of sleeve of ZA alloy, but also offer some new thoughts for the design of extrusion mold.

Multistage Cold Extrusion Process and Forming Rules of Shaft Parts Used in Gearbox

2010 ◽  
Vol 148-149 ◽  
pp. 683-687
Author(s):  
Dong Sheng Ji ◽  
Jun Song Jin ◽  
Wei Jie Ma ◽  
Ju Chen Xia ◽  
Han Guan Xia ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Formation Mechanism ◽  
Element Model ◽  
Production Method ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Forming Process ◽  
Mechanical Coupling ◽  
Extrusion Technology

The production method of a driving axles used in gearbox is presented in this paper. A five-stage cold extrusion technology for forming the driving axle was made. First, simulations based on thermal-mechanical coupling finite element model were performed with Deform_2D. During the forming process, the concave appeared at the shaft end. And its formation mechanism was studied. Then the forming rules were obtained. Corresponding experiments were carried out and quality forging was achieved. Simulation and experimental results both indicate that the five-stage cold extrusion technology was feasible.

scholarly journals Research on Improvement of Cold Extrusion Technology of Connecting Screw

2022 ◽  
Vol 2160 (1) ◽  
pp. 012055
Author(s):  
Yuhong Yuan ◽  
Yu Ren ◽  
Quan Wu
Keyword(s):  
Metal Flow ◽  
Dimensional Accuracy ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Forming Process ◽  
Deformation Law ◽  
New Process ◽  
Simulation Results ◽  
Extrusion Forming ◽  
Extrusion Technology

Abstract In order to solve the flange and dent defects in the end face of the cold extrusion of the connecting screw, the Deform3D software is used to simulate the extrusion forming process of the connecting screw, and the velocity vector is used to study the metal flow law of the part in the cold extrusion process. According to the velocity field and deformation law obtained by the simulation, the end face depression defect in the forming process is predicted. An improved production process is proposed, and the simulation results show that the new process scheme effectively eliminates the “sag” defect on the end face of the part. Finally, the extruded parts with qualified dimensional accuracy are obtained through experiments, and the results are basically consistent with the simulation results.

Simulation Study on Influence of Forming Process Parameters on Backward Extrusion Height of 6061 Aluminum-Alloy Wheel

2011 ◽  
Vol 121-126 ◽  
pp. 363-366
Author(s):  
Lu Li ◽  
Fang Wang
Keyword(s):  
Aluminum Alloy ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Forming Process ◽  
6061 Aluminum Alloy ◽  
Backward Extrusion ◽  
Punch Speed ◽  
Alloy Wheel ◽  
Forming Temperature ◽  
Extrusion Technology

Backward extrusion process of aluminum-alloy wheel forging is analyzed by the finite element method. The influence of punch speed and forming temperature on the backward extrusion height of 6061 aluminum alloy wheel is discussed. Studies show that the backward extrusion height increases with increasing forming temperature, and with decreasing punch speed at the same deformation load. It is indicated that when the ranges of forming temperature is from 450 to 500°C and the punch speed is 0.5-1 mm/s, the aluminum alloy wheel has the optimal forming quality. The analysis and conclusions in this paper are helpful in developing the hot extrusion technology specification of 6061 aluminum alloy.

Microstructuring by a Combination of Micro Impact Extrusion and Shear Displacement Forming

2013 ◽  
Vol 554-557 ◽  
pp. 893-899 ◽  
Author(s):  
Andreas Schubert ◽  
Stephan F. Jahn ◽  
Benedikt Müller
Keyword(s):  
Cross Sections ◽  
Material Flow ◽  
Extrusion Process ◽  
Shear Displacement ◽  
Raw Material ◽  
Hybrid Process ◽  
Research Centre ◽  
Forming Process ◽  
Process Chains ◽  
Production Technologies

The Collaborative Research Centre SFB/TR 39 PT-PIESA is developing mass production technologies and process chains for the fabrication of aluminium piezo composites, which can be used as raw material for "smart sheet metal" [1]. Microstructuring by forming is a challenging task concerning material flow, tool and process design [2]. In this study, a hybrid forming process combined of micro impact extrusion and shear displacement is presented and discussed. The formed microstructure, depicted in figure 1, consists of ten parallel primary cavities with cross sections of 0.3×0.3 mm² and four larger secondary cavities which are surrounding the primary cavities. High demands are made concerning precision and reproducibility of the cavities' geometry according to the function of the cavities, which is to serve as collets for sensitive piezo rods. The microstructure has to be formed with one stroke of the stamp. Micro backward impact extrusion is chosen for structuring the primary cavities since it allows accurate forming without aligning die plate and stamp due to a flat die plate. Shear displacement forming, which is the selected process for the secondary cavities, requires a structured and aligned die plate but the forming forces are significantly lower than forming the same geometry with an extrusion process which in turn increases the accuracy. The investigations are focused on the characterization of samples formed with the hybrid process in comparison to structures which are formed solely by impact extrusion. Geometric parameters, material flow and process parameters were evaluated to assess the hybrid process. First experiments show promising results, whereas higher degrees of deformation could be reached at lower forming forces. Exemplary, sections for both processes are depicted in figure 2.

Study on Conductive Properties of Composites Based on the In-Mold Laminating Technology

2012 ◽  
Vol 501 ◽  
pp. 402-406
Author(s):  
Yan Zhong ◽  
Peng Cheng Xie ◽  
Wei Min Yang ◽  
Yu Mei Ding
Keyword(s):  
New Technology ◽  
Polymer Melt ◽  
Processing Parameters ◽  
Extrusion Process ◽  
The Novel ◽  
Novel Device ◽  
Pp Composites ◽  
Extrusion Technology ◽  
Conductive Properties ◽  
Properties Of Composites

This paper introduced a new co-extrusion process which could increase layers by lamination-torsion-combination of polymer melt. The in-mold laminating technology was a kind of microlayed co-extrusion technology. The feasibility of the new technology on processing of polymer was validated. Conductive polypropylene filled with carbon black/polypropylene (PPCB/PP) composites was prepared using the novel device, the effects of processing parameters on conductivity of composites were researched. The results showed that the percolation threshold can decrease greatly.

scholarly journals The Research of the Cold Extrusion Shaping Technology of the Tubular Component with Oral Part Having Flange

2012 ◽  
Vol 4 ◽  
pp. 121-124
Author(s):  
Zhi Hong Yu
Keyword(s):  
Die Design ◽  
Cold Extrusion ◽  
Forming Process ◽  
Improvement Measures ◽  
Extrusion Technology ◽  
Cold Stamping ◽  
Tubular Component

In the basis of researching the shaping methods to the tubular component with oral part having flange, the varieties of feasible forming process schemes are analyzed comprehensively under the premise of ensuring not rupture, with combination of many forming processes such as cold extrusion, cold stamping and upsetting. In the middle of cold extrusion shaping of the tubular component with oral part having flange, in the light of solid blank selected, the varieties of technology schemes that are utilized flexibly in the production are proposed and the problems existed in the schemes are compared and analysed and the corresponding prevention and improvement measures are put forward. In the production of the tubular component with oral part having flange, the cold extrusion technology is used to give the reference to a certain extent to the similar parts of forming process and die design.

scholarly journals Numerical Simulation and Experimental Study on Rotary Cold Extrusion Forming of Screw Rod

2021 ◽  
Vol 2101 (1) ◽  
pp. 012017
Author(s):  
Peiai Li ◽  
Baoyu Wang ◽  
Jiapeng Wang
Keyword(s):  
Wall Thickness ◽  
Extrusion Process ◽  
Simulation Software ◽  
Cold Extrusion ◽  
Extrusion Force ◽  
Forming Process ◽  
Material Loss ◽  
Screw Pump ◽  
Plastic Forming ◽  
Extrusion Forming

Abstract The rotary cold extrusion forming process is a plastic forming process with very low material loss, especially in the production of hollow screw rods with equal wall thickness. In this work, the rotary cold extrusion forming process of a hollow T2 copper screw rod with a wall thickness of 4 mm and solid T2 copper screw rod was verified by experimental method. The finite element simulation software Deform-3D was also used to simulate the rotary cold extrusion forming process of the screw rod. The effects of the die with different heights of the working belt and the different wall thickness of the billet on the eccentricity, extrusion force, and forming torque in the forming process of the screw rod were studied. The results show that it is feasible to process hollow and solid T2 copper screw rods with equal wall thickness by rotary cold extrusion. With the increase of die working belt height, the eccentricity of the screw rod becomes smaller and closer to the ideal eccentricity. With the increase of the wall thickness of the billet, the amplitude fluctuation range of the eccentricity of the screw rod gradually decreases. The higher the height of the die working belt, the greater the extrusion force and torque required in the extrusion process, and the more intense the change of torque. These results also provide theoretical guidance for the production practice and lightweight transformation of the screw pump rotor.

Computer Simulation of Forming Technology of Thin Aluminum Engine Cylinder Liners Based on LS-DYNA

2012 ◽  
Vol 203 ◽  
pp. 290-294
Author(s):  
Han Wu Liu ◽  
Hong De Ren ◽  
Han Xun Lv
Keyword(s):  
Aluminum Alloy ◽  
Spray Deposition ◽  
Equivalent Stress ◽  
Stress Gradient ◽  
Cylinder Liner ◽  
High Strength ◽  
Extrusion Process ◽  
Forming Process ◽  
Engine Cylinder ◽  
Spinning Process

The high-silicon aluminum alloy by spray deposition forming is well suited for the engine cylinder liner because of the need of high strength and abrasion resistance, but its forming process is much complex, and many process parameters are involved. In order to lower the investments of time, labor power and money due to the traditional processing methods that need to adjust the craft parameters frequently, the thermal extrusion process and the spinning process that are the most important forming processes in aluminum alloy cylinder liner forming are simulated by the finite element simulation technology. It is found that during the extrusion process, the equivalent stresses near the die are larger, and uneven, the stress gradient is very large, but the maximum stress does not exceed the allowable stress of the material through the numerical simulation; In the spinning process, the stress and deformation are larger at the beginning of the process, but they will have a slight decreasing with the spinning process going on. Throughout the spinning process, the equivalent stress and strain distribution of the spinning component maintained a relatively balanced state basically, which is consistent with the later experimental results. It proves the reliability of the the simulation.

Numerical Modeling of the Hot Forming Process of Composite Materials

2019 ◽  
Author(s):  
Hao Wang ◽  
Bo Li ◽  
Zongyue Fan ◽  
Xiaobai Li
Keyword(s):  
Composite Materials ◽  
Orientation Distribution ◽  
Processing Parameters ◽  
Raw Material ◽  
Hot Forming ◽  
Forming Process ◽  
Mesh Free ◽  
Thermomechanical Simulation ◽  
Simulation Results ◽  
Strengthening Particles

Abstract We present a fully coupled thermomechanical simulation of the hot forming process of composite materials. The raw material is a mixture of resin powders, strengthening particles and reinforcing fibers. Complex material responses in the process, such as phase change (melting and polymerization) and reorientation of the fibers, determine the microstructure and the performance of the final product. A phase-aware incremental mesh-free Lagrangian method is presented to overcome the challenges, which combines the Optimal Transportation Meshfree (OTM) method and the variational thermomechanical constitutive updates, and simulation results including the compression ratio, material properties of the final product and orientation distribution of fibers are recorded. By comparing the simulation results with the experimental measurements, the computational framework is validated, which enables robust and efficient analysis of the sensitivity of the performance of composite materials on their processing parameters.

Forming Analysis of AZ80 Magnesium Alloy Thick-Walled Tube Fabricated by Hydrostatic Shrinkage Extrusion

2019 ◽  
Vol 950 ◽  
pp. 80-84
Author(s):  
Yang Li ◽  
Ren Shu Yuan
Keyword(s):  
Magnesium Alloy ◽  
High Performance ◽  
Equivalent Stress ◽  
Extrusion Ratio ◽  
Forming Process ◽  
Az80 Magnesium Alloy ◽  
Forming Analysis ◽  
Series Of Experiments ◽  
Extrusion Technology ◽  
3D Software

In order to obtain high performance magnesium alloy thick-walled tubes, the magnesium alloy ingot was extruded by hydrostatic shrinkage extrusion technology. Through a series of experiments, it was found that the magnesium alloy tube was not formed in the extrusion ratio that is smaller than 2.11 . Deform-3D software was used to simulate the tube forming process under different extrusion ratios. It was noting that at the condition of the extrusion ratio of 2.11, the equivalent stress and strain of the extruded tube at the fixed sizing zone were obviously unevenly distributed, which was disappeared with the increase of the extrusion ratio. Compared with the homogenized magnesium alloy , the yield strength, the tensile strength and the elongation were improved when the tensile test was carried out on the extruded magnesium alloy thick-walled tube. These results clearly showed that the mechanical properties of magnesium alloy tubes were improved after hydrostatic extrusion.

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