Numerical Simulation of the Effect of Feedstock Shape on Continuous Extrusion Process

2012 ◽  
Vol 472-475 ◽  
pp. 2004-2008 ◽  
Author(s):  
Li Chen ◽  
Bao Yun Song ◽  
Xin Bing Yun
Keyword(s):  
Metal Flow ◽  
Flow Characteristics ◽  
Extrusion Process ◽  
Forming Process ◽  
Section Shape ◽  
Wheel Torque ◽  
Metal Deformation ◽  
Continuous Extrusion ◽  
Extrusion Forming ◽  
3D Software

Since the appearance of the continuous extrusion process, the section shape of the feedstock is round. The shape of the feedstock directly affects metal deformation and metal flow characteristics during the continuous extrusion process. Based on finite element method (FEM), using the Deform-3D software, this paper simulates continuous extrusion forming process for copper bus bar, and analyzes the effect of different feedstock shape on metal flowing temperature, velocity, rotating torque. The results show that: the size of the rectangular feedstock must be within a reasonable range, otherwise the continuous extrusion process can not be established; the rectangular feedstock is benefit to the flow uniformity comparing with the round feedstock; the temperature of the billet and tooling with rectangular feedstock is lower than that with round feedstock, as the feedstock width increases, the temperature decreases and the area of high temperature becomes smaller; the change of the feedstock shape and size has no effect on the extrusion wheel torque value.

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.

Experimental and Numerical Investigation of Rubber Extrusion Forming for Multi Material Automobile Weather Strip

2011 ◽  
Vol 462-463 ◽  
pp. 831-836
Author(s):  
Seyyed Mohammad Javadi ◽  
Elham Alizadeh ◽  
Behnam Rahimi ◽  
Amir Hosseini
Keyword(s):  
Finite Volume ◽  
Minimum Degree ◽  
Flow Characteristics ◽  
Extrusion Process ◽  
Least Square ◽  
Low Velocity ◽  
Forming Process ◽  
Computational Code ◽  
Balanced Flow ◽  
Extrusion Forming

Rubber extrusion process is the most complex and important problem in the production of automobile weather strips. To achieve a specified geometry for an extrudate profile, together with a minimum degree of pressure loss, flow balancing of die is required. To attain this objective, the flow characteristics in die channel must be accurately described, and this demands a computational code able to predict complex 3D flow patterns. In this paper, experimental data and tree-dimensional finite volume simulations of the melted rubber flow in die region, during extrusion forming process are presented. For melted rubber flow modeling, the conservation equations of mass, momentum, and energy are solved using a 3D computational code based on the finite volume method. The shear viscosity of the melted rubber flow is described by the power-law and Arrhenius-law models, and the governing equations parameters are interpolated by the least-square fitting of experimental values that gained by Rubber Process Analyzer (RPA). The flow in one of two dies, called plate die, is found to be highly unbalanced. In the second die, by using a feeder plate, the flow at the exit of the die was properly balanced. Experimental results show that for a die with balanced flow rate, extruded profile closely matches the designed profile. Also, reveal that in low-velocity regions of die exit, the profile section tend to contraction.

FVM Simulation of the Effect of Preventing Ring Structure on Continuous Extrusion Process

2011 ◽  
Vol 314-316 ◽  
pp. 767-771
Author(s):  
Li Chen ◽  
Bao Yun Song ◽  
Xiao Dong Luan
Keyword(s):  
Plastic Deformation ◽  
Fe Simulation ◽  
Metal Flow ◽  
Extrusion Process ◽  
Ring Structure ◽  
Middle Part ◽  
Continuous Extrusion ◽  
Volume Method ◽  
Extrusion Forming ◽  
Opening Width

Continuous extrusion is an advanced process for manufacturing copper bus-bar while preventing ring is an important factor affecting forming. Due to the severe plastic deformation, FE simulation of continuous extrusion extending deforming is inaccurate and inefficient because of frequent remesh. Based on finite volume method (FVM) which can avoid re-mesh effectively, this paper simulates continuous extrusion forming, and analyzes the effect of different preventing ring structure on metal flowing velocity. The results show that: preventing ring with the curve transitional surface is beneficial to metal uniform flowing than that with the plane transitional surface; As radius of preventing ring increases, the metal flow rate of the sides is faster than the middle part; As opening width of preventing ring increases, the dead metal zones become smaller in the middle area.

An Analysis of the Effect of Feedstock on Continuous Extrusion Forming Process

2011 ◽  
Vol 127 ◽  
pp. 506-510 ◽  
Author(s):  
Li Chen ◽  
Bao Yun Song ◽  
Yuan Wen Liu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Industrial Application ◽  
Forming Process ◽  
Copper Strip ◽  
Rotating Speed ◽  
Continuous Extrusion ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

Continuous extrusion is an advanced process for manufacturing copper strip. Its successfully industrial application is to manufacture copper strip. Based on finite element method (FEM), using the Deform-3D software, this paper simulates continuous extrusion forming process for copper strip, and analyzes the effect of different feedstock diameter on metal flowing temperature, effective stress, velocity, rotating torque. The results show that: feedstock diameter greatly affects the continuous extrusion forming process; Under the same rotating speed, as feedstock diameter increases, the metal flowing velocity increases. It is benefit to enhance the productivity; As feedstock diameter increases, the temperature of the billet and tooling increases, and the torque of extrusion wheel increases, which leads to tooling wear seriously.

scholarly journals Research on Improvement of Cold Extrusion Technology of Connecting Screw

2022 ◽  
Vol 2160 (1) ◽  
pp. 012055
Author(s):  
Yuhong Yuan ◽  
Yu Ren ◽  
Quan Wu
Keyword(s):  
Metal Flow ◽  
Dimensional Accuracy ◽  
Extrusion Process ◽  
Cold Extrusion ◽  
Forming Process ◽  
Deformation Law ◽  
New Process ◽  
Simulation Results ◽  
Extrusion Forming ◽  
Extrusion Technology

Abstract In order to solve the flange and dent defects in the end face of the cold extrusion of the connecting screw, the Deform3D software is used to simulate the extrusion forming process of the connecting screw, and the velocity vector is used to study the metal flow law of the part in the cold extrusion process. According to the velocity field and deformation law obtained by the simulation, the end face depression defect in the forming process is predicted. An improved production process is proposed, and the simulation results show that the new process scheme effectively eliminates the “sag” defect on the end face of the part. Finally, the extruded parts with qualified dimensional accuracy are obtained through experiments, and the results are basically consistent with the simulation results.

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.

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 Microstructural and mechanical studies of feedstock material in continuous extrusion process

2021 ◽  
Vol 16 (1) ◽  
Author(s):  
Tariku Desta ◽  
Devendra Kumar Sinha ◽  
Perumalla Janaki Ramulu ◽  
Habtamu Beri Tufa
Keyword(s):  
Yield Strength ◽  
Statistical Significance ◽  
Extrusion Process ◽  
Wheel Speed ◽  
Forming Process ◽  
Percentage Elongation ◽  
Continuous Forming ◽  
Before And After ◽  
Continuous Extrusion ◽  
Feedstock Material

AbstractThe challenge encountered in continuous forming process is the variation in mechanical strength of product formed with respect to process variables like extrusion wheel speed and diameter of product. In this research article, the micro-structural investigation of the aluminum (AA1100) feedstock material of 9.5-mm diameter has been carried out at various extrusion wheel speeds and diameter of product before and after deformation on commercial continuous extrusion setup TBJ350. The mechanical properties like yield strength as well as percentage elongation have been estimated and optimized using two variables with 3 levels through central composite rotatable design (CCRD) method. The mathematical modeling has been carried out to predict the optimum combination of process parameters for obtaining maximum value of yield strength and percentage elongation. The statistical significance of mathematical model is verified through analysis of variance (ANOVA). The optimum value of yield strength is found to be 70.939 MPa at wheel velocity of 8.63 rpm and product diameter of 9 mm respectively, whereas the maximum percentage elongation recorded is 46.457 at wheel velocity of 7.06 rpm and product diameter of 7.18 mm. The outcome may be useful in obtaining the best parametric combination of wheel speed and extrusion ratio for best strength of the product.

Research the process of cold punching of hex nut blanks of increased height

2019 ◽  
Vol 75 (8) ◽  
pp. 979-984
Author(s):  
I. G. Shubin ◽  
A. A. Kurkin ◽  
A. R. Bazykov ◽  
F. A. Stolyarov
Keyword(s):  
Strain State ◽  
Metal Flow ◽  
Geometrical Parameters ◽  
Stress Strain ◽  
Industrial Testing ◽  
Stress Strain State ◽  
Metal Deformation ◽  
3D Software ◽  
Through Hole ◽  
Power Costs

The high nuts withstand increased load for expansion, facilitating its even distribution along the bolt length. The process of increased height nut blanks plastic deformation characterized by uneven metal flow and changing of stressed state by the blank section. In the process of closed-die stamping of such nuts a risk of their geometry distortion arises. Results of study of the process of production a hex nut of increased height presented. The object of the research was to study the process of the metal deformation when broach a hole for thread in a hexagonal nut blank of increased height. To simulate the stress-strain state, the QForm-3D software package was chosen, which made it possible to predict with sufficient accuracy the metal flow in the blank, calculate the deformation forces and determine the stresses that occur in the tool. The models of the blank and the tool were created in the Compass 3D program without internal and external defects. When performing the work, the parameters of the stress-strain state of a hexagonal nut blank of increased height were calculated. The simulation results showed the need to change the geometry of the end part of the punch to a conical one with an angle of 150 degrees and a reduction in the size of the baffle height from 10.4 mm to 5.4 mm. The adopted changes allowed to reduce the energy and power costs of forming a through hole for the threads. Industrial testing confirmed the correctness of the calculations. Nuts with edges perpendicular to its base and the required geometrical parameters were obtained.

Prediction of Forces and Damage at Forming Sheet on Multipoint Die

2014 ◽  
Vol 656 ◽  
pp. 215-222 ◽  
Author(s):  
Marius Costin Manea ◽  
Damian Timofte ◽  
Stefan Velicu
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Sheet Metal ◽  
Computer Software ◽  
Forming Process ◽  
Element Simulation ◽  
Metal Deformation ◽  
Materials Used ◽  
Titanium Grade ◽  
3D Software

This paper presents aspects of a simulation based on multi-point die optimization sheet metal deformation using for types of materials: titanium grade 1, aluminium 2024, carbon steel 1010 and 1137. Due to processing methods of the sheet metal appeared, multi-point deformation is a very interesting process industry. For the finite element simulation of sheets metal using multi-point die was chosen Deform 3D software. Simulations were performed for four types of materials used in the construction industry. With the development of computer software, specialized programs appeared on the market forming process simulation, for determining the stresses and strains of the deformed material, the distribution of temperature field, how the material is flowing, the final form of the product, etc. Modeling and numerical simulation of deformation processes can be viewed at any time of their deployment, which allows rethinking solutions for problems arising in the process. Also by this method of finite element simulation can be optimized in the design engineering processes and tools.

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