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.

Design of Pocket Dies for Metal Extrusion Using the Finite Element Method

2014 ◽  
Vol 709 ◽  
pp. 87-93
Author(s):  
Khemajit Sena ◽  
Surasith Piyasin
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Material Flow ◽  
Extrusion Process ◽  
The Finite Element Method ◽  
Extrusion Dies ◽  
Extrusion Die ◽  
Cross Section Area ◽  
Metal Extrusion ◽  
Element Method

Metal extrusion is currently very beneficial for producing workpieces with long dimensions or when a uniform cross section area is required. Design of extrusion dies, which results to the shape, geometry and size of the workpiece, is the main factor for quality, productivity and durability of the products. Besides improving the bearing length, a die pocket is a good solution to effectively control the velocity of material flow into the die hole. Therefore, this study aimed to evaluate the structures of die pockets that influence the material flow in the extrusion process. Thus, the finite element method (FEM) was used to determine the parameters that affect the strength of the extrusion die due to the maximum stresses which occurred on the die and pocket. From this study, it was found that the circular shaped pocket with 31degrees pocket angle, 22 mm pocket die thickness and made of titanium alloy provided the maximum strengths and safety factors. This result from the simulations can sufficiently predict the risk of damages on the extrusion die and pocket for further extension of the tool’s life cycle.

Parallel Extrusion of Aluminum Alloy Heat Sink with Round-Fin

2013 ◽  
Vol 739 ◽  
pp. 131-135
Author(s):  
Li Han Zhang ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Jia Yu Ying
Keyword(s):  
Heat Sink ◽  
Material Flow ◽  
Extrusion Process ◽  
Element Analysis ◽  
Automotive Lighting ◽  
Metal Sheets ◽  
The Finite Element Analysis ◽  
Alloy Heat ◽  
Flow Through ◽  
Good Agreement

Parallel extrusion is a combined extrusion process for forming round-fin heat sink on thick metal sheets. In this paper, the parallel extrusion has been applied to manufacture the round-fin heat sink in the automotive lighting. Numerical simulations on the round-fin heat sink forming using the software DEFORM were carried out. The tooling structure with counterpressure on the heat sink formation was investigated. The results show that the tooling structure with counterpressure is helpful to the formation of round-fin heat sink, which not only ensures the height of each round-fin on the heat sink is uniform but also retards the initiation of flow-through on the reverse side of round-fin. In addition, the experiments of press forging process were conducted to validate the finite element analysis, it is shown that the friction at the punch-blank interface has more significant effect on preventing the initiation of flow-through compared with the friction at the die-blank interface, which implies that the punch-blank interface has more significant effect on the material flow in the formation of round-fin, and the simulation results are in good agreement with the experimental data.

Newest Developments on the Manufacture of Helical Profiles by Hot Extrusion

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Material Flow ◽  
Twist Angle ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
3D Fem ◽  
Extrusion Dies ◽  
Application Fields ◽  
Twisting Angle ◽  
Screw Rotors

A new innovative direct extrusion process, helical profile extrusion (HPE) is presented, which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction and the material flow on the twisting angle and contour accuracy. By means of finite-element method (FEM), the profile shape could be improved by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. Mainly, the friction in the die influences the twist angle and the shape of the helical profile. Two die coatings were analyzed, but the friction was not substantially decreased in any of these cases. Although there is no efficient practical solution for reducing the friction in extrusion dies using tested die coatings, the required profile contour could be achieved by new die designing and by modifying the material flow. However, increasing the twist angle is limited due to geometrical aspects of this technology, namely, by the ratio of the volume to the contact area with the die for the displaced metal.

Press Forging Forming of the Round-Fin on Heat Sink

2013 ◽  
Vol 706-708 ◽  
pp. 448-451
Author(s):  
Chong Chao Lin ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Li Han Zhang
Keyword(s):  
Friction Coefficient ◽  
Friction Factor ◽  
Heat Sink ◽  
Material Flow ◽  
Extrusion Process ◽  
Metal Sheets ◽  
Flow Through ◽  
Good For

Press forging forming is a combined extrusion process for forming round-fin on heat sink on thick metal sheets. A series of simulations on the round-fin forming using the program DEFORM were carried out. The blank thickness and friction coefficient on the formation of round-fin were studied. The results show that the blank thickness is very good for the round-fin formation, and the thicker the blank is, the better the round-fin can be formed; and also when both the punch-blank interface and the die-blank interface have the same value of friction factor, the larger value of friction factor is in favor of round-fin forming, the further investigation reveals that the friction at the punch-blank interface has more significant effect on preventing the initiation of flow-through compared with the friction at the die-blank interface, which implies that the punch-blank interface has more significant effect on the material flow in the formation of round-fin.

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.

Simulation of the Co-Extrusion of Hybrid Mg/Al Profiles

2009 ◽  
Vol 424 ◽  
pp. 113-119 ◽  
Author(s):  
Jerome Muehlhause ◽  
Sven Gall ◽  
Sören Müller
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Composite Materials ◽  
Material Flow ◽  
Extrusion Process ◽  
The Finite Element Method ◽  
Porthole Die ◽  
Single Production ◽  
Element Method

Extrusion of composite materials can offer big advantages. In this work the manufacturing of a hybrid metal profile in a single production step was investigated. A porthole die was used, thus producing profiles with extrusion seams. Along the seams a material mix up was visible. The extrusion process was simulated with the Finite Element Method to investigate the material flow in die and welding chamber in order to understand the cause for the defects at the seams.

Shape Optimization for Weight Reduction of Polymer Extrusion Die

2015 ◽  
Vol 799-800 ◽  
pp. 261-265
Author(s):  
Tao Huang ◽  
Yan He ◽  
Yi Nie ◽  
Yan Wang ◽  
Yueh Jaw Lin ◽  
...  
Keyword(s):  
Shape Optimization ◽  
Lightweight Design ◽  
Minimum Weight ◽  
Flow Characteristics ◽  
Optimization Method ◽  
Extrusion Process ◽  
Polymer Extrusion ◽  
Extrusion Dies ◽  
Extrusion Die ◽  
Element Simulation

Polymer extrusion is one of the most widely utilized manufacturing processes across many industries including automotive, architecture, aerospace etc. However, in order to maintain normal operations, polymer extrusion dies are conventionally designed with large dimensions and thick walls which results in the overweight of them. In this paper, a shape optimization method is proposed to reduce the weight of polymer extrusion dies without sacrificing the required performances of extrudate. Firstly, Finite element simulation of the extrusion process is conducted using the commercial software HyperXtrude to study both the essential flow characteristics of polymer melts and the deformation and stress distribution of extrusion die. Secondly, shape optimization is conducted to find the minimum weight of extrusion die while satisfying the required properties and productivity of polymer product. The extrusion die is then redesigned according to the result of shape optimization and compared with the original one. A Medium-sized polymer profile extrusion die is selected as case study, the result of which shows that the weight of the extrusion die is reduced by 31.6%,though the maximal deformation and stress of the die are increased by 1.7% and 16.1% respectively. The proposed approach is demonstrated to be effective for the lightweight design of polymer extrusion die.

The Design of Damping Block in the Tire Tread Extrusion Die

2013 ◽  
Vol 446-447 ◽  
pp. 356-359
Author(s):  
Peng Fei Wen ◽  
Ping Ping Xu ◽  
Kai Ding
Keyword(s):  
Optimum Design ◽  
Orthogonal Experiment ◽  
Flow Process ◽  
Finite Element Software ◽  
Extrusion Dies ◽  
Extrusion Die ◽  
Orthogonal Experiment Method ◽  
Flow Through ◽  
Head Channel ◽  
Tread Rubber

It is one of the keys that determining reasonable damping block geometry in the process of designing the extrusion dies. In this paper, the finite element software POLYFLOW was used to simulate the flow process of tread rubber in the head channel. In addition, the orthogonal experiment method was adopted for the optimum design of the damping block in the head channel. After optimum design, the flow velocity of rubber melt becomes more uniform in the full width at the head outlet. Consequently, the warping deformation of the rubber, which flow through the head channel, is also significantly reduced.

Simulations of a Fox-Rabies Epidemic on an Island Using Space-Time Finite Elements

1990 ◽  
Vol 45 (11-12) ◽  
pp. 1230-1240 ◽  
Author(s):  
Gwen A. Gardner ◽  
Leslie R. T. Gardner
Keyword(s):  
Numerical Model ◽  
Finite Elements ◽  
Field Data ◽  
Reaction Diffusion ◽  
Space Time ◽  
Reaction Diffusion Equations ◽  
Diffusion Equations ◽  
Two Dimensional ◽  
Dimensional Models

Abstract The two-dimensional reaction diffusion equations for the spread of rabies in a logistically growing fox population are solved numerically. The method, based upon Galerkin’s approach, uses space-time finite elements. The numerical model is shown, quantitatively, to possess the essential features of earlier one and two-dimensional models and to reproduce the values of field data accurately. A more realistic illustration of the use of the model, a study of the spread of rabies over the Isle of Anglesey, is then discussed.

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