Studies on Process Parameters for Aluminum Extrusion of Slide Rails

2013 ◽  
Vol 467 ◽  
pp. 392-397 ◽  
Author(s):  
Shun Yu Shao ◽  
Wen Yen Wang ◽  
Yi An Chen
Keyword(s):  
Aluminum Alloy ◽  
Process Design ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Roll Forming ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Extrusion Die ◽  
Simulation Results ◽  
Product Weight

Slide rails are usually fabricated by roll forming and are used in kitchenware and cabinets mostly. However the product weight of slide rails is increased because larger dimensions are required to bear larger load when they are used in dies and warehouses. International suppliers start to develop Aluminum slide rails to decrease the product weight in recent years. The manufacturing and functional feasibility of Aluminum slide rail were discussed in this study. The Aluminum slide rail was designed according to ready-made slide rail, and the aluminum alloy was selected with required mechanical properties. The suitable extrusion die was designed and direct extrusion parameters of extrusion ratio, extrusion temperature, extrusion speed and extrusion load are also considered. The extrusion process of aluminum alloy was simulated by CAE software to check the mold and process design. The extrusion part of aluminum slide rail was carried out by extruder to verify the simulation results.

Modeling of Aluminum Extrusion Process Using Non-Orthogonal Block Structured Grids Based FVM

2011 ◽  
Vol 189-193 ◽  
pp. 1749-1752
Author(s):  
Rui Wang ◽  
Hong Zhong Li
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Special Treatment ◽  
Aluminum Extrusion ◽  
Rigid Plastic ◽  
Structured Grids ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Die Extrusion

The mathematic model of 3D aluminum extrusion processes using finite volume method (FVM) was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Non-orthogonal structured grids were used to match complex geometric boundaries and local refinement of grids was also realized. The collocated arrangement is used to discretize the governing equations on non-orthogonal grids directly, pressure oscillations bring by this arrangement and error caused by grid’s non-orthogonality is eliminated by special treatment. A pocket die extrusion process was simulated using the program developed in this paper. The simulation results were also compared with that simulated by FEM software Deform in the same process, material and die conditions. The feasibility and efficiency of the mathematic model built in this paper was demonstrated by the simulation results and the comparison.

Numerical Simulation of Al 6062 Alloy Deformation Behavior Using Equal Channel Angular Extrusion Process with Different Die Angles

2015 ◽  
Vol 813-814 ◽  
pp. 557-562
Author(s):  
Aitha Lavanya ◽  
Perumalla Janaki Ramulu ◽  
G. Sreekanth Kumar ◽  
P. Ramya Sree ◽  
Sirish Battacharya ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Metal Forming ◽  
Equal Channel Angular Extrusion ◽  
Frictional Coefficient ◽  
Maximum Load ◽  
Extrusion Process ◽  
Outer Corner ◽  
Cylindrical Billet ◽  
Angular Extrusion ◽  
Simulation Results

The equal channel angular extrusion (ECAE) is one of the most important methods used for bulk metal forming. In which die angles are the most importent parameter. This paper attempts to determine the effect of different die angles during ECAE process for 6062 aluminum alloy deformation. Numerical simulations are performed for ECAE process on cylindrical billet of 6062 aluminum alloy at a constant frictional coefficient (μ) of 0.08 and punch speed of 15 mm/sec. Die has made with inner corner angles of (φ) =105°, 115°, 125°and 135° by fixing the outer corner angle (ψ) of 6°, punch is designed with a radii (R) of 4.75mm and height of 50mm. From the simulation results, tha data has been obtained in the form of load stroke behavior, and energy consumend during the punch stoke. It is observed that the maximum load and more energy consumption during the process is noted for lower angle.

Aluminum Rod Extrusion and Material Modeling

2008 ◽  
Vol 367 ◽  
pp. 71-78
Author(s):  
P.T. Moe ◽  
Yawar Abbas Khan ◽  
Henry Sigvart Valberg ◽  
Sigurd Støren
Keyword(s):  
Temperature Measurement ◽  
Constitutive Relations ◽  
Simulated Data ◽  
Thermal Conditions ◽  
Extrusion Process ◽  
Material Modeling ◽  
Outlet Temperature ◽  
Aluminum Extrusion ◽  
Scientific Approach ◽  
Simulation Results

The article presents an outline of a scientific approach for testing constitutive relations for the aluminum extrusion process. By comparing ram force, container friction, die face pressure, outlet temperature measurement during rod extrusion with corresponding simulated data, inferences can in principle be drawn with respect to the validity models. The paper indicates that simulation results from the 2D ALMA2π program are in fair agreement with measurements during extrusion of AA6060, but more work needs to be done to control thermal conditions during extrusion.

Extrusion Benchmark 2013 - Experimental Analysis of Mandrel Deflection, Local Temperature and Pressure in Extrusion Dies

2013 ◽  
Vol 585 ◽  
pp. 13-22 ◽  
Author(s):  
Alessandro Selvaggio ◽  
Thomas Kloppenborg ◽  
Martin Schwane ◽  
Ramona Hölker ◽  
Andreas Jäger ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Experimental Investigations ◽  
Measurement Equipment ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Statistical Validation ◽  
Extrusion Dies ◽  
Special Measurement ◽  
Die Temperature ◽  
Temperature And Pressure

A bridge die was designed for the simultaneous extrusion of two rectangular profiles and used in a strictly monitored aluminum extrusion process. Experimental investigations aimed at the measurement of the mandrel deflection, the local die temperature, and the pressure inside the welding chamber by means of special measurement equipment. AA6082 alloy was used as extrusion material. The influence of the extrusion speed on the aforementioned objectives is reported. The experiments were repeated at least three times under the same conditions in order to achieve a statistical validation of the acquired data. These data are provided as reference for the 2013 edition of the Extrusion Benchmark.

Extrudability and Bonding Strength of Copper Clad Aluminum Alloy Composites Produced by Indirect Extrusion Process

2007 ◽  
Vol 26-28 ◽  
pp. 417-420
Author(s):  
Hyouk Chon Kwon ◽  
Taek Kyun Jung ◽  
Jang Won Kang ◽  
H.J. Lee ◽  
K.H. Kim ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Diffusion Layer ◽  
Bonding Strength ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Core Material ◽  
Surface Fracture ◽  
Sem Observation ◽  
The Core ◽  
Sheath Material

This paper described extrudability and bonding strength of copper (TPC) clad aluminum alloy (pure Al, Al3003, Al5005, and Al7072) composites produced by indirect extrusion at 350°C with extrusion ratio of 21.39. Conical typed die with semi angle of 30°. Carbon oil was used to reduce the friction between billet/sleeve and billet/die. Maximum extrusion pressure was estimated to 491MPa for the Cu/Al, 714MPa for the Cu/Al3003, 820MPa for the Cu/Al5005, and 743MPa for the Cu/Al7072 alloy composites. No surface fracture was observed. From SEM observation, diffusion layer between the sheath material and the core material of extruded composites is observed and its thickness was measured to about 1.5㎛. The bonding strength was estimated to 65MPa for the Cu/Al, 89.3MPa for the Cu/Al3003, 70MPa for the Cu/Al5005, and 75MPa for the Cu/Al7072 alloy composites.

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.

FVM Simulation of Large Deformational Aluminum Extrusion Process and Die Bearing Optimization

2010 ◽  
Vol 97-101 ◽  
pp. 400-403
Author(s):  
Rui Wang
Keyword(s):  
Three Dimensional ◽  
Mathematic Model ◽  
Extrusion Process ◽  
Complex Geometries ◽  
Aluminum Extrusion ◽  
Aluminum Profile ◽  
Simulation Results ◽  
Volume Method ◽  
Aluminum Profile Extrusion ◽  
Deform 3D

The mathematic model of three-dimensional aluminum profile extrusion processes using finite volume method (FVM) was established in this paper. Basic theory and key technologies of this model were researched and built. Non-orthogonal blocked structured girds were used to fit complex geometries. Volume of Fluid (VOF) scheme was used to capture the free surface of the deforming materials. A program AE-FVM was written according to the above theories and equations. A thin walled aluminum profile extrusion process was simulated and optimized using AE-FVM. The simulation results were also compared with that simulated by Deform-3D and SuperForge in the same conditions. The feasibility of the mathematic model built in this paper was demonstrated by the simulation results comparison.

scholarly journals Micro-Extrusion Process And Microstructure Evolution of Miniature Heat Pipe In 6063 Aluminum Alloy

2021 ◽  
Author(s):  
Yongda Liu ◽  
Jie Xu ◽  
Zhengwu Zhang ◽  
Gang Liu ◽  
Debin Shan ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Size Effect ◽  
Heat Pipe ◽  
Microstructure Evolution ◽  
Material Flow ◽  
Shape Control ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
6063 Aluminum Alloy ◽  
Ram Speed

Abstract Micro-extrusion process of miniature heat pipe with axial micro grooves is particularly difficult due to ultra-large extrusion ratio and complex cross-sectional shape. In this study, the shape control of a miniature heat pipe in 6063 aluminum alloy with boundary dimension of 5×4 mm has been successfully realized during micro-extrusion. Micro-extrusion process and microstructure evolution of the miniature heat pipe were investigated by the combination of finite element (FE) analysis with experiments. The results show that material flow deformation behavior during micro-extrusion is highly affected by size effect, and lower ram speed is conductive to forming integrity, dimension accuracy and surface quality of the heat pipe profile. The primary mechanism for micro-extrusion failure of micro-grooves is severely more uneven material flow between the micro rib and base region at higher ram speed, which is caused by size effect and results in shear deformation and even fractures of micro rib. Further research shows that, compared to the extrusion using as-cast billets, much coarser grains were obtained after micro-extrusion using as-extruded billets at an ultra-large extrusion ratio of 205. Besides that, the entirely different texture components after extrusion were obtained instead of the typical < 100 > //ED or < 111 > //ED fiber texture components. These atypical texture components can be regarded as texture deviating from ideal texture by a certain angle (15° or 20°) along φ axis or φ1 axis.

Study on the Intelligent Design System of Square Tube Aluminum Profile Extrusion Processes Based on VB

2012 ◽  
Vol 549 ◽  
pp. 884-888
Author(s):  
Zhi Ping Zhang ◽  
Han Wu Liu ◽  
Xiao Xia Li
Keyword(s):  
Programming Language ◽  
Intelligent Design ◽  
Extrusion Process ◽  
Design System ◽  
Aluminum Extrusion ◽  
Forming Process ◽  
Extrusion Die ◽  
Aluminum Profile ◽  
Extrusion Forming ◽  
Aluminum Profile Extrusion

According to the similar characteristics of structure, geometry and constraints conditions in the same type of extrusion process, the intelligent design system of a square tube aluminum profile extrusion forming process was established in this paper based on the VB programming language, with using parametric programming language APDL provides by ANSYS software. The parameterized optimization design plan of pre-treatment and post-processing of ANSYS analysis during a square tube aluminum extrusion forming process was achieved, and the program of a three-dimensional model of the extrusion die under Visual Lisp environment was also programmed. The human-computer interaction intelligent design system which combined with pre-processing of semi-finished product, finite element analysis of extrusion die strength, extrusion die temperature field analysis, structural optimization of the die was realized. The research results show that the system can provide program decision-making, structural design, performance analysis and graphics treatment for the actual extrusion productions of square tube aluminum extrusion process, which reduced the design time of the technical staff, and saved design cost.

An optimizing process of profiled cross-sectional aluminum alloy porthole die extrusion using response surface methodology

2016 ◽  
Vol 30 (08) ◽  
pp. 1650098 ◽  
Author(s):  
Fujian Zhou ◽  
Feng Li ◽  
Liansheng Shi ◽  
Hongwei Jiang
Keyword(s):  
Aluminum Alloy ◽  
Friction Factor ◽  
Cross Section ◽  
Ultimate Load ◽  
Initial Temperature ◽  
Extrusion Process ◽  
Extrusion Speed ◽  
Porthole Die ◽  
Die Extrusion ◽  
Porthole Die Extrusion

The porthole die extrusion process of profiled cross-section hollow aluminum alloy is influenced by numerous factors, which brings inconvenience to the process design. In this paper, 7075 aluminum alloy is taken as an example, the fitting model of the ultimate load is analyzed by variance and regression analysis using response surface method (RSM). The influences of extrusion speed, friction factor and initial temperature on the change of extruded ultimate load are investigated systematically, and the important influence factors (initial temperature [Formula: see text] friction factor [Formula: see text] extrusion speed) to the load are determined eventually. By comparison, the error between the ultimate load model obtained after fitting and the calculated value is only 2.4%, further verifying the reliability of this model. The optimal objective is to minimize the ultimate load, then the optimum technological parameters are obtained by optimizing the process, where the initial temperature, the extrusion speed and the friction factor are 430[Formula: see text]C, 2.28[Formula: see text]mm/s and 0.31, respectively. The results provide a theoretical basis for the scientific design of the porthole die extrusion process of profiled cross-section hollow aluminum alloy.

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