Effects of Welding Chamber Step on Extrusion Process of a Complex Hollow Profile

2010 ◽  
Vol 148-149 ◽  
pp. 1684-1688 ◽  
Author(s):  
Hao Chen ◽  
Guo Qun Zhao ◽  
Cun Sheng Zhang ◽  
Jiang Wei Liu
Keyword(s):  
Quality Control ◽  
Numerical Model ◽  
Product Quality ◽  
Cross Section ◽  
Metal Flow ◽  
Extrusion Process ◽  
Weld Quality ◽  
Extrusion Die ◽  
Temperature Distributions ◽  
Welding Pressure

The extrusion die is of great importance in the quality control of profile production. Yet in practice, the design of extrusion die is mainly dependent on the experience and intuition of die designers, which is difficult to guarantee product quality and productivity. In this paper, a numerical model was developed based on HyperXtrude with an attempt to investigate the effects of the shape of the welding chamber on metal flow and weld quality. The porthole dies with different steps of welding chamber were designed and applied to extrude an identical profile. Numerical results showed that with an increasing step of welding chamber, more uniform velocity and temperature distributions in the cross-section of the extrudate were observed. In addition, the weld quality was improved owing to increasing welding pressure, when adopting the multi-step welding chamber.

Analysis of Metal Flow of Aluminum through Long Choked Die Channels

2009 ◽  
Vol 424 ◽  
pp. 145-152 ◽  
Author(s):  
Henry Sigvart Valberg
Keyword(s):  
Cross Section ◽  
Channel Wall ◽  
Metal Flow ◽  
Extrusion Process ◽  
Sliding Contact ◽  
Aluminum Extrusion ◽  
Grid Pattern ◽  
Contact Conditions ◽  
New Knowledge ◽  
Flow Through

The mechanics of metal flow through long choked die channels have been investigated in unlubricated hot aluminum extrusion. Experiments were performed in a laboratory press at an earlier occasion by letting a grid pattern introduced into the billet flow down into the choked die channel to appear adjacent to the channel wall. The grid pattern was then revealed to characterize the metal flow in the channel. A 2D-model of the extrusion process was made. The model was applied to study the conditions in the extrusion experiments and in this model good similarity was obtained with the experiment. New knowledge regarding the metal flow through a choked die channel have been obtained this way, such as; contact conditions, presence of sticking and sliding zones, friction conditions in the sliding contact zone and the velocity profile over the cross-section of the channel.

Numerical Analysis of Four-Hole Extrusion of Aluminum Alloys

2009 ◽  
Vol 424 ◽  
pp. 173-179 ◽  
Author(s):  
W. Libura ◽  
Artur Rękas ◽  
D. Leśniak
Keyword(s):  
Numerical Analysis ◽  
Aluminum Alloys ◽  
Product Quality ◽  
Deformation Zone ◽  
Flow Direction ◽  
Metal Flow ◽  
Flow Analysis ◽  
Extrusion Process ◽  
Fem Simulations ◽  
6061 Aluminium Alloy

The work presents the results of FEM simulations of extrusion process with the use of four – hole dies of various geometry. The traditional flat dies and pocket dies were adopted for comparison. The calculations were conducted for indirect extrusion of rods of 14 mm in diameter from the 6061 aluminium alloy. The distributions of strains, stresses, metal velocities and temperature within the deformation zone were the basis for metal flow analysis. Based on the conducted calculations the die configuration, leading to the best product quality was recommended. The product quality was evaluated by the flow direction of rods from the die orifices.

Effects of Multi-Step Welding Chamber on Extrusion Product Quality and Die Strength

2010 ◽  
Vol 44-47 ◽  
pp. 311-315
Author(s):  
Hao Chen ◽  
Guo Qun Zhao ◽  
Cun Sheng Zhang ◽  
Dao Sheng Wen
Keyword(s):  
Product Quality ◽  
Maximum Stress ◽  
Metal Flow ◽  
Extrusion Process ◽  
Porthole Die ◽  
Die Life ◽  
Die Extrusion ◽  
Extrusion Product ◽  
Porthole Die Extrusion ◽  
Key Parameter

The shape of welding chamber is a key parameter in flat porthole die extrusion process, which influences product quality and die life-span directly. In this paper, by means of numerical simulation of the extrusion process for an aluminum hollow profile, the effects of multi-step welding chamber on metal flow and die strength have been investigate. The numerical results revealed that the multi-step welding chamber was effective to balance metal flow in the die cavity. In addition, with an increasing step of welding chamber, the maximum stress and deflection of the lower die decreased, while the deflection of the mandrel kept almost unchanged and the maximum stress of upper die increased.

scholarly journals Optimization of the Die Topology in Extrusion Processes

2008 ◽  
Vol 43 ◽  
pp. 81-88 ◽  
Author(s):  
Thomas Kloppenborg ◽  
Marco Schikorra ◽  
Jan P. Rottberg ◽  
A. Erman Tekkaya
Keyword(s):  
Numerical Model ◽  
Finite Elements ◽  
Material Flow ◽  
Extrusion Process ◽  
Two Dimensional ◽  
Extrusion Dies ◽  
Porthole Die ◽  
Extrusion Die ◽  
Flow Through ◽  
The Difference

This paper presents the results of investigations on topology optimizations in extrusion dies. The change of material viscosity of finite elements in the numerical model is utilized to allow or to block the material flow through the finite elements in simplified two-dimensional extrusion models. Two different optimization procedures are presented. In the first part of the paper dead zones in a flat and in a porthole die were improved by enhance the streamlining of the extrusion die. In the second part an evolutionary optimization algorithm has been used to optimize the extrusion die topology in order to reduce the difference between the strand exit velocities in a multi extrusion process. Finally, both methods were sequentially combined.

Finite Volume Simulation in Porthole Dies Extrusion of Aluminum Profiles

2011 ◽  
Vol 291-294 ◽  
pp. 290-296
Author(s):  
Lei Cheng ◽  
Shui Sheng Xie ◽  
You Feng He ◽  
Guo Jie Huang ◽  
Yao Fu
Keyword(s):  
Numerical Simulation ◽  
Finite Volume ◽  
Cross Section ◽  
Process Analysis ◽  
Flow Behavior ◽  
Metal Flow ◽  
Extrusion Process ◽  
Porthole Die ◽  
Simulation Results ◽  
Aluminum Profiles

FEM simulation of aluminum profiles in porthole die extrusion process using Lagrange mesh description will inevitably bring mesh self-contact, severe grid distortion and frequent remeshing, which will result in the loss of computational accuracy and excessive calculation time. In order to solve the above mentioned problems, numerical simulation of aluminum profiles with large and complicated cross-section in extrusion process was achieved using finite volume method based on Euler mesh description. The metal flow behavior and welding course was investigated in detail, which can provide the theoretical guide for porthole die design and optimization. In addition, extrusion experiment was carried out by numerical simulation results. The experimental extrudate was in good agreement with the simulation results, which laid a good solid foundation for non-steady state extrusion process analysis of large scale and complicated cross-section profiles.

Numerical Simulation and Die Design for Vibration Extrusion of Spur Gear

2012 ◽  
Vol 580 ◽  
pp. 37-41
Author(s):  
Qiong Lin ◽  
Bin Meng ◽  
Qing Hua Yang
Keyword(s):  
Numerical Simulation ◽  
Flow Characteristic ◽  
Metal Flow ◽  
Spur Gear ◽  
Extrusion Process ◽  
Die Design ◽  
Forming Process ◽  
Extrusion Die ◽  
Die Structure ◽  
Metal Extrusion

The numerical simulation for spur gear vibration extrusion is performed in this paper. The metal flow characteristic and load-stroke relationship during forming process is analyzed and then compared with traditional metal extrusion process. The results revealed the axial vibration of cavity die can both reduce forming load and benefit for metal flow, which could achieve better forming quality. Finally according to the processing requirements, the vibration generator and whole extrusion die structure is designed.

Study on the Guiding Chamber Effect on Welding Pressure in Hollow Extrusion Die Design

2010 ◽  
Author(s):  
Quang-Cherng Hsu ◽  
Ping-Hsun Tsai
Keyword(s):  
Aluminum Alloy ◽  
Flow Behavior ◽  
Metal Flow ◽  
Die Design ◽  
High Yield ◽  
Design Parameters ◽  
Element Analysis ◽  
Suitable Material ◽  
Extrusion Die ◽  
Welding Pressure

In order to increase the welding pressure of the hollow Al7075 tube in extrusion process, a special die feature has been created. Several different proportions of chamber structure in outlet of extrusion die have been designed. The finite element analysis software DEFORM 3D to analyze various design parameters on the load–displacement and the welding pressure have been studied. Comparing to 6000 series, 7000 series aluminum alloy have good material properties, including excellent strength and toughness especially for hollow aluminum extrusion products in terms of Al7075. However, in extruded hollow aluminum alloy products, the industry’s common use is 6000 series material, except for indirectly extruded seamless pipe, Al7075 can be found. This is because of less welding pressure can be provided by using the traditional die structures in Al7075 hollow products. Therefore, to use the directly extruded seam tube of Al7075 in high-yield and high-quality, to increase the welding pressure and improve the quality of welding products becomes a very important issue. In this study, a different high proportion in material guiding chamber has been defined. The same angle both on the exit of female die and the bearing of male die which can be integrated into a material guiding chamber has been designed. Therefore, the welding pressure can be increased due to the change of metal flow behavior that is after a complete fill in material guiding chamber, and then metal can flow out of die bearing surface. The results showed that welding pressure can be increased rapidly if a suitable material guiding chamber has been built. Among them, the ratio of chamber height and length is 2:1; the increased welding pressure is most significant.

scholarly journals EFFECTS OF GUIDING CHAMBER ON WELDING PRESSURE IN HOLLOW EXTRUSION DIE DESIGN OF AA7075

2018 ◽  
Vol 54 (5A) ◽  
pp. 191
Author(s):  
Do Anh Tuan
Keyword(s):  
Aluminum Alloy ◽  
Extrusion Process ◽  
Die Design ◽  
Design Parameters ◽  
Element Analysis ◽  
Suitable Material ◽  
Hollow Section ◽  
Extrusion Die ◽  
Welding Pressure ◽  
Aluminum Alloy Tube

Porthole die extrusion has a great advantage in the forming of hollow section of aluminum alloy tube. This paper aims at the development of an extruding seam square tube of AA7075 high strength aluminum alloy. In order to increase the welding pressure of the hollow AA7075 tube in extrusion process, a special die feature has been created. Several different proportions of chamber structure in outlet of extrusion die have been designed. The finite element analysis software DEFORM 3D to analyze various design parameters on the load – displacement and the welding pressure have been studied. In this study, a different high proportion in material guiding chamber has been defined. The results showed that if a suitable material guiding chamber has been built then welding pressure can be increased rapidly. When the ratio of chamber height and length is 2:1 the increased welding pressure is the best.

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

SYSTEM APPROACH TO COAL PRODUCT QUALITY CONTROL

2017 ◽  
Vol 17 (6) ◽  
pp. 13-24
Author(s):  
E.V. Freydina ◽  
◽  
E.V. Freydina ◽  
A.A. Botvinnik ◽  
A.N. Dvornikova ◽  
...  
Keyword(s):  
Quality Control ◽  
Product Quality ◽  
System Approach ◽  
Product Quality Control ◽  
Coal Product
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