The Effect of Lubricant Viscosity in Cold Work Forward Extrusion

2014 ◽  
Vol 554 ◽  
pp. 291-295
Author(s):  
Samion Syahrullail ◽  
Shunpei Kamitani ◽  
Kenji Nakanishi
Keyword(s):  
Sliding Friction ◽  
Pure Aluminum ◽  
Cold Work ◽  
Metal Flow ◽  
Extrusion Process ◽  
High Viscosity ◽  
Extrusion Force ◽  
Workpiece Surface ◽  
Forward Extrusion ◽  
Lubricant Viscosity

In cold work extrusion, lubricants play an important role in lubricating the tool and workpiece surfaces, preventing metal-to-metal contact and reducing sliding friction, so that the workpiece can be extruded smoothly without severe wear due to lubricant starvation. In this paper, the influence of lubricant viscosity in cold work forward extrusion was investigated. The lubricants were additive-free, paraffinic mineral oil, which may have low, medium or high viscosity. The workpiece material was pure aluminum A1100, extruded with extrusion ratio of 3. The analysis focused on extrusion force, workpiece surface roughness after the extrusion process and the metal flow in the deformation zone of the workpiece. Using the visioplasticity method, the sliding velocity was calculated from the metal flow. Results showed that, the higher the lubricant viscosity, the lower the extrusion force generated. However, a high-viscosity lubricant produces coarser workpiece surface conditions after the extrusion process.

Evaluation of Paraffinic Mineral Oil as Lubricant in Cold Work Extrusion Process

2014 ◽  
Vol 554 ◽  
pp. 327-331 ◽  
Author(s):  
Samion Syahrullail ◽  
Mohd Ahyan Nurul Aini
Keyword(s):  
Plane Strain ◽  
Pure Aluminum ◽  
Cold Work ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Experimental Result ◽  
Friction Effect ◽  
Billet Material ◽  
Deformation Area ◽  
Taper Die

In this paper, the effect of frictional constraint from the application of three different viscosity of additive free paraffinic mineral oil as lubricant were investigated by cold work forward plane strain extrusion experiments. The experiment used a cold work plane strain extrusion apparatus consist of a pair of taper die and a symmetrical workpiece (billet). The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the higher viscosity, will lead to lower friction effect to the deformed area, as well as product area.

Study on Extrusion Forming of Superalloy Tube under Different Dies

2010 ◽  
Vol 145 ◽  
pp. 380-385
Author(s):  
Yi Lun Mao ◽  
Qing Dong Zhang ◽  
Chao Yang Sun
Keyword(s):  
Temperature Rise ◽  
Metal Flow ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Steel Tube ◽  
Flow Rule ◽  
Extrusion Force ◽  
Tube Extrusion ◽  
Extrusion Die ◽  
Inconel 690

Extrusion die is a key factor in tube extrusion deformation. This paper, studying Inconel 690 alloy steel tube hot extrusion process by adopting Deform-2D software, analyses the influence of flat dies, cone die and flat-cone die on extrusion force, temperature rise, and metal flow rule during superalloy extrusion process and find that cone die is more helpful for superalloy tube extrusion. Based on it, the influence rule of cone die angle on extrusion force and temperature rise is studied, and the best die angle for superalloy tube extrusion is provided, which offer the evidence for the design of superalloy tube extrusion die

Experimental Study of a Full Forward Extrusion Process from Metal Strip

2012 ◽  
Vol 504-506 ◽  
pp. 587-592 ◽  
Author(s):  
Marion Merklein ◽  
Tommaso Stellin ◽  
Ulf Engel
Keyword(s):  
Extrusion Process ◽  
Metal Strip ◽  
Raw Material ◽  
High Rate ◽  
Process Chain ◽  
Forward Extrusion ◽  
Bulk Forming ◽  
Material Conditions ◽  
Set Up ◽  
Tooling System

A high rate of production of complex microparts is increasingly required by fields like electronics and micromechanics. Handling is one of the main problems, limiting those forming processes of small metal components consisting of multiple forming stages. A forming chain in which a metal strip acts both as raw material and support of the workpiece through the different stages of the process, is seen as a solution that radically simplifies the positioning of microparts. Each workpiece stays connected to the strip through all the forming steps, being separated just at the end of the process chain. In this work, a tooling system for the bulk forming from copper strips has been set up and employed in a full forward extrusion process of a micro-billet. The same die, with a diameter of 1 mm, has been used with three different strip thicknesses (1, 2 and 3 mm) and three different material conditions. The use of thinner and hard-as-rolled strips has resulted in achieving a higher ratio of the billet length to strip thickness.

scholarly journals Experimental Investigation of the Equal Channel Forward Extrusion Process

Metals ◽  
2015 ◽  
Vol 5 (1) ◽  
pp. 471-483 ◽  
Author(s):  
Mahmoud Ebrahimi ◽  
Faramarz Djavanroodi ◽  
Sobhan Tiji ◽  
Hamed Gholipour ◽  
Ceren Gode
Keyword(s):  
Experimental Investigation ◽  
Extrusion Process ◽  
Forward Extrusion

Hydrostatic Extrusion With Controlled Follower Block Clearance

1975 ◽  
Vol 97 (1) ◽  
pp. 25-31 ◽  
Author(s):  
K. M. Kulkarni ◽  
J. A. Schey
Keyword(s):  
Ambient Temperature ◽  
Surface Finish ◽  
Extrusion Ratio ◽  
Hydrostatic Extrusion ◽  
Extrusion Force ◽  
Processing Conditions ◽  
Surface Processing ◽  
Specimen Diameter ◽  
Lubricant Viscosity ◽  
Breakthrough Pressure

Hydrostatic extrusion of annealed 1100 aluminum was investigated experimentally at ambient temperature. The principal variables studied were lubricant viscosity which was varied from less than 100 to over 76,000 SUS at 100 deg F and the diametral clearance between the follower block and the extrusion cylinder which ranged from 0.0005 to 0.0030 in. for the 1.026 in. dia. cylinder. The specimen diameter was 0.97 or 1.00 in. corresponding to an extrusion ratio of 4.75 or 5.00, respectively. The included die angle was either 60 deg or 90 deg. The results show that with a proper combination of the lubricant viscosity and the follower block clearance, hydrostatic extrusion can be accomplished without the necessity of any sealing of the container on the follower block side. The optimum clearance for minimum breakthrough pressure increases as the lubricant viscosity increases. The extrusion force increases with die angle. The paper discusses the various factors that affect the magnitude of the breakthrough pressure and the occasional uneven bamboo-type appearance of the surface. Processing conditions must be selected carefully since the lowest extrusion force does not necessarily lead to a product with the best surface finish.

Research on Influence of Process Parameters on Sheet Metal Extrusion Force

2009 ◽  
Vol 16-19 ◽  
pp. 515-519
Author(s):  
Hua Xiang ◽  
Xin Cun Zhuang ◽  
Zhen Zhao
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Fem Simulation ◽  
Extrusion Process ◽  
Orthogonal Experimental Design ◽  
Extrusion Force ◽  
Influence Of Process Parameters ◽  
Tool Shape ◽  
Simulation And Experiment ◽  
Metal Extrusion

Extrusion force plays a significant role on sheet metal extrusion process. It is characterized by various process parameters including material properties, extrusion ratio, friction, tool shape etc. In this paper, a reasonable FEM model of sheet metal extrusion process was established and validated by comparing the results of simulation and experiment firstly. Based on the reliable model, the effect on extrusion force of various process parameters was investigated with orthogonal experimental design combined FEM simulation. The work presented in this paper has laid certain foundation for further work of modeling and optimizing extrusion force.

Metaheuristic Approaches for Extrusion Manufacturing Process

2018 ◽  
pp. 43-56 ◽  
Author(s):  
Pauline Ong ◽  
Desmond Daniel Vui Sheng Chin ◽  
Choon Sin Ho ◽  
Chuan Huat Ng
Keyword(s):  
Extrusion Process ◽  
Flower Pollination Algorithm ◽  
Trial And Error ◽  
Optimal Parameters ◽  
Flower Pollination ◽  
Forward Extrusion ◽  
Comparable Performance ◽  
Trial And Error Method ◽  
Nature Inspired Algorithms ◽  
Error Method

Optimization, basically, is a method used to find solutions for a particular problem without neglecting the existing boundaries or limitations. Flower Pollination Algorithm (FPA) is one of the recently developed nature inspired algorithms, based on the intriguing process of flower pollination in the world of nature. The main aim of this study is to utilize FPA in optimizing cold forward extrusion process in order to obtain optimal parameters to produce workpiece with the minimum force load. It is very important to find the most optimal parameters for an extrusion process in order to prevent waste from happening due to trial and error method in determining the optimal parameters and thus, FPA is used to replace the traditional trial and error method to optimize the cold forward extrusion process. The optimization performance of the FPA is then compared with the particle swarm optimization (PSO), in which the FPA shows comparable performance in this regard.

Use of Electron Backscatter Diffraction Technique in Characterization of 6XXX Aluminum Alloy Extrusions

2000 ◽  
Vol 6 (S2) ◽  
pp. 954-955
Author(s):  
Steven R. Claves ◽  
Wojciech Z. Misiolek ◽  
William H. Van Geertruyden ◽  
David B. Williams
Keyword(s):  
Electron Backscatter Diffraction ◽  
Metal Flow ◽  
Extrusion Process ◽  
Cross Sectional ◽  
Electron Backscattering Diffraction ◽  
Electron Backscatter ◽  
Individual Grains ◽  
Backscatter Diffraction ◽  
6Xxx Series

Electron Backscattering Diffraction (EBSD) is an important tool for analyzing the crystal grain orientation of a microstructure and can be used to formulate conclusions about microtexture, texture determined from individual grains. This technique has been used to study a 6xxx series aluminum alloy's response to the deformation of the extrusion process. Extrusion is the process by which a billet of material is forced, under high pressure, through a die. The material undergoes a significant decrease in cross sectional area, and is formed into a shape equivalent to the geometry of the die orifice. Different bearing lands are shown in shown in Figure 1. These surfaces form the part, and are designed to control the metal flow making it uniform through the die, thus yielding good mechanical properties. This research was focused on the resultant microstructure. The shaded regions of Figure 2 show the two surface regions where EBSD measurements were taken.

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