Cold Extrusion Process Analysis of "Seven-Speed Sleeve" and Forming Parameter Optimization

2011 ◽  
Vol 199-200 ◽  
pp. 1924-1927
Author(s):  
Rong Xia Chai ◽  
Chen Guo ◽  
Hong Qi Hu ◽  
Li Yu Zhang
Keyword(s):  
Process Parameters ◽  
Process Analysis ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Extrusion Speed ◽  
Entrance Angle ◽  
Production Practice ◽  
Die Structure ◽  
3D Software ◽  
Deform 3D

The scheme for cold extrusion process of Seven-speed sleeve is determined according to the experiences and analysis by DEFORM-3D software, the extrusion procedure has been numerical simulation analyzed; The part technology and parameters of die structure has been optimized by orthogonal test. The optimized process parameters are as following: friction factor is 0.10, blank height is 31.4mm, extrusion speed is 200mm/s; The optimized parameters of die structure are as following: 1st step convex fillet is 1.5mm, 1st step concave rounded is 2.0mm, 2nd step convex fillet is 2.0mm, 2nd step concave rounded is 1.0mm, 1st step die-entrance angle is 35°, 2nd step die-entrance angle is 60°.The qualified products are obtained using the optimized process parameters in the production practice.

Effect of Process Parameters on the Microstructure Homogeneity of AA6082 Aluminum Alloy Deformed by Twist Extrusion

2013 ◽  
Author(s):  
V. S. Senthil Kumar ◽  
U. Mohammed Iqbal
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Effective Strain ◽  
Extrusion Process ◽  
Work Piece ◽  
Hardness Testing ◽  
Twist Extrusion ◽  
Experimental Values ◽  
3D Software ◽  
Deform 3D

Twist extrusion is a severe plastic deformation in which the rectangular shaped work piece is extruded through a die with a twist channel. In this work the twist extrusion process of AA6082 T6 aluminum samples were carried out to investigate the effects of process parameters like temperature and deformation passes on the microstructure homogeneity. The results indicate that the grain refinement of AA 6082 T6 aluminum alloy leads to inhomogeneous microstructure after one twist extrusion pass. On further extrusion passes the inhomogeneity in the microstructure is found to be disappeared. The homogeneity of the distribution of the deformation was confirmed by micro hardness testing. Finite element modeling has been performed in DEFORM 3D software for determining the homogeneity of the effective strain distribution which agreed well with the experimental values.

Simulation of Cold Extrusion Process of Hollow Pieces

2013 ◽  
Vol 446-447 ◽  
pp. 270-274
Author(s):  
Jia Long Ren ◽  
Xiao Xia Chen ◽  
Chun Yan Zhang ◽  
Xiao Fei Liu
Keyword(s):  
Strain Field ◽  
Cone Angle ◽  
Metal Flow ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Metal Deformation ◽  
3D Software ◽  
The Impact ◽  
Deform 3D ◽  
Virtual Velocity

The impact of friction factor, thickness of the cold extrusion, semi-cone angle and other factors on cold extrusion was analyzed. Various process parameters were set and optimized. Cold extrusion process of hollow pieces was simulated by DEFORM-3D software. Through the simulation of the virtual velocity field, strain field, stress field, load - stroke curve and metal deformation process, the flow velocity of the metal and the deformation of the workpiece were studied. The metal flow routes and the parts that are easy to wear in die were gained. The above research results provide valuable references for the processing of hollow pieces.

Influence of Heating Models on Necking Deformation during Tube Extrusion Process

2011 ◽  
Vol 189-193 ◽  
pp. 1778-1781 ◽  
Author(s):  
Gui Hua Liu ◽  
Yong Qiang Guo ◽  
Zhi Jiang
Keyword(s):  
Temperature Gradient ◽  
Material Flow ◽  
Extrusion Process ◽  
Work Piece ◽  
Tube Extrusion ◽  
Deformation Parameters ◽  
Flow Features ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

By using Deform-3D software, the necking extrusion forming processes of integer trailer axle with two different heating means which are Uniform Heating (UH) method and Partly Heating (PH) method with temperature gradient are simulated. The influence of deformation parameters such as friction factor, necking coefficient, different temperature distribution of work-piece on the material flow features, stress and strain field, loading force and deformation process are analyzed in detail. According to the numerical simulation results, using PH method with temperature gradient can improve necking deformation during tube extrusion process.

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.

Influence of Friction on Metal Flow Behaviour and Die Stress of Backward Extrusion

2011 ◽  
Vol 117-119 ◽  
pp. 1719-1722
Author(s):  
Yong Shun Yang ◽  
Tian Tian Yin ◽  
Ke Feng
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Extrusion Process ◽  
Flow Behaviour ◽  
Backward Extrusion ◽  
Die Stress ◽  
3D Software ◽  
Deformation Area ◽  
Deform 3D ◽  
Unit Pressure

In the paper, the Deform-3D software was used to simulate the mechanism of metal flow behaviour under the influence of different friction in the backward extrusion process, and further study its influence on die stress. The numerical simulation demonstrates that: smaller friction could reduce difficult deformation area of extrusion metal significantly; friction state not only affected the plastic deformation extent, but also would increase the consumption of extrusion energy; the unit pressure of punch and stress of inner wall increased along with the increase of friction, meanwhile, the ratio of them increased as well.

scholarly journals A Special Extrusion-shear Manufacturing Method for Magnesium Alloy Rods Based on Finite Element Numerical Simulation and Experimental Verification

2022 ◽  
Author(s):  
Ou Zhang ◽  
Hongjun Hu ◽  
Huiling Zhang ◽  
Hui Zhao ◽  
Ding-fei Zhang ◽  
...  
Keyword(s):  
Magnesium Alloy ◽  
Metal Flow ◽  
Temperature Fields ◽  
Extrusion Speed ◽  
Manufacturing Method ◽  
Grain Sizes ◽  
Friction Factors ◽  
Finite Element Numerical Simulation ◽  
3D Software ◽  
Deform 3D

Abstract To research the influences of process parameters on a special extrusion-shearmanufacture method for magnesium alloy rods, deform-3d software with finite elementsimulations has been used to analyze the material flows of deformed magnesium alloysAZ31B during the extrusion-shear (ES) process, as well as the grain sizes anddistribution of extrusion loads, stresses and strains, and blank temperatures. Temperaturefields, stress fields, strain fields and temperature fields varying with different blankpreheating temperatures, extrusion speed and extrusion ratios were simulated. Influences ofdifferent extrusion conditions and different die structures on microstructures of rods prepared by ES process has been researched. Extrusion forces decrease with the increasing extrusion temperatures, decreasing extrusion ratios, increasing die channel angles and decreasing friction coefficients. The flow velocities of metal in the ES die increase with development of ES process. Increasing the channel angles and reducing the friction factors would increase the outflow velocities of metal, but it has little effect on the uniformity of metal flow. The increase in friction and extrusion speed would increase the temperatures of the ES die. The ES process can prepare finer and more uniform microstructures than those prepared by direct extrusion under the same conditions.

Plastic Deformation Simulation on Compound Twist Extrusion Process for Metal Materials

2013 ◽  
Vol 291-294 ◽  
pp. 2676-2679 ◽  
Author(s):  
Yong Zhi Li ◽  
Xue Fei Du
Keyword(s):  
Plastic Deformation ◽  
Severe Plastic Deformation ◽  
Effective Strain ◽  
Extrusion Process ◽  
Ultrafine Grained ◽  
Twist Extrusion ◽  
The Subject ◽  
Intensive Investigation ◽  
3D Software ◽  
Deform 3D

Severe plastic deformation（SPD）methods have been the subject of intensive investigation for preparing bulk ultrafine-grained materials in recent years. This paper introduces a new severe plastic deformation (SPD) process named as C-TE process which combines the Twist Extrusion with Extrusion against the asymmetric deformation of TE process. and the distribution of effective strain and stress of the sample and the variation of load with time and its influence on the deformation were investigated by computer simulation with Deform-3D software . The results reveal that C-TE process can significantly slow uniform phenomenon,and a sample of homogeneous deformation can be obtained by the improved process.

Simulation of Compound Cold Extrusion Al-Zn-Mg-Cu Alumium Alloys

2012 ◽  
Vol 159 ◽  
pp. 257-261
Author(s):  
Zhi Ming Zhou ◽  
Wei Jiu Huang ◽  
Zhen Zhao ◽  
Bin Bin Lei ◽  
Chun Liu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Automotive Industry ◽  
Maximum Stress ◽  
Effective Strain ◽  
High Strength ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Processing Route ◽  
Deep Hole ◽  
Deform 3D

Al-Zn-Mg-Cu super-high strength aluminum alloy is widely used in the aerospace and automotive industry. However, the extrudability of Al-Zn-Mg-Cu aluminum alloy is relatively poor compared with other series of aluminum alloys. The simulation of compound cold extrusion process of Al-Zn-Mg-Cu aluminum alloy was studied for the production of a double-cup workpiece with a deep wobbler hole in this paper. The effective strain and stress distribution of the alloy during cold extrusion were studied by Deform-3D simulation. The results show that the maximum stress was concentrated at the bottom of the deep hole. Cracks were easily to be occured near the bottom of deep-hole. Based on the experimental results, the processing route of the two steps with compound cold extrusion is more suitable than one cold extrusion for the production.

Contrasting Models to Determine the Approximate Extrusion Process Conditions for the First Billet

2009 ◽  
Vol 424 ◽  
pp. 249-256
Author(s):  
Marc Sabater ◽  
Maria Luisa García-Romeu
Keyword(s):  
Neural Networks ◽  
Process Parameters ◽  
Extrusion Process ◽  
Predictor Variables ◽  
Process Conditions ◽  
Extrusion Speed ◽  
Billet Temperature ◽  
Regression Techniques

This paper is focused on determining extrusion process conditions for the first billet and, particularly, on selecting an adequate billet temperature and extrusion speed. It is important to predict these values before adjusting the die to avoid lengthy and unproductive preparation times, and to make die adjustment easier during the tests. With that in mind, this study employs two models to determine the first billet temperature (TFB) and the extrusion speed (SE) parameters: one that applies regression techniques and another that uses neural networks. The aim of this paper is to present the results obtained by comparing the performance of the two models to determine which one offers the best results. We also analyze whether changing the number of patterns for construction of the models will improve results. The models are based on extrusion process parameters taken from real industry contexts. The results indicate that the variables chosen as predictor variables for the extrusion speed output must be refined.

Process Analysis for Spindle Support Rolling Thread

2013 ◽  
Vol 433-435 ◽  
pp. 1127-1130
Author(s):  
Ya Bei Shi ◽  
Sun Yang
Keyword(s):  
Production Process ◽  
Process Analysis ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Feed Speed ◽  
Shaping Time ◽  
Thread Rolling ◽  
Thin Walled ◽  
Traditional Production ◽  
Process Method

Traditional production process for hollow thin-walled thread rolling is not enough. Cold extrusion process method for hollow thin-walled thread rolling is introduced principally with spindle support in this paper. It is practiced by means of spindle support in general rolling machine. Some process are explain in detail, such as select of support Spindle size, choose of rolling strength, select feed speed, lengthen shaping time and so on

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