Extrusion Benchmark 2013 - Experimental Analysis of Mandrel Deflection, Local Temperature and Pressure in Extrusion Dies

2013 ◽  
Vol 585 ◽  
pp. 13-22 ◽  
Author(s):  
Alessandro Selvaggio ◽  
Thomas Kloppenborg ◽  
Martin Schwane ◽  
Ramona Hölker ◽  
Andreas Jäger ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Experimental Investigations ◽  
Measurement Equipment ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Statistical Validation ◽  
Extrusion Dies ◽  
Special Measurement ◽  
Die Temperature ◽  
Temperature And Pressure

A bridge die was designed for the simultaneous extrusion of two rectangular profiles and used in a strictly monitored aluminum extrusion process. Experimental investigations aimed at the measurement of the mandrel deflection, the local die temperature, and the pressure inside the welding chamber by means of special measurement equipment. AA6082 alloy was used as extrusion material. The influence of the extrusion speed on the aforementioned objectives is reported. The experiments were repeated at least three times under the same conditions in order to achieve a statistical validation of the acquired data. These data are provided as reference for the 2013 edition of the Extrusion Benchmark.

Extrusion Benchmark 2009 Experimental Analysis of Deflection in Extrusion Dies

2009 ◽  
Vol 424 ◽  
pp. 19-26 ◽  
Author(s):  
Daniel Pietzka ◽  
Nooman Ben Khalifa ◽  
Lorenzo Donati ◽  
Luca Tomesani ◽  
A. Erman Tekkaya
Keyword(s):  
Temperature Distribution ◽  
Tool Steel ◽  
Experimental Analysis ◽  
Extrusion Process ◽  
Statistical Distribution ◽  
Experimental Investigations ◽  
Aluminum Extrusion ◽  
Extrusion Dies ◽  
Hot Work Tool Steel ◽  
Die Material

In this paper experimental investigations aimed at measuring the die deformations during aluminum extrusion process is presented and discussed. A two-holes die generating two U-shape profiles with different supporting legs was produced and tested under strictly monitored conditions. The influence of die deformation on the speed, temperature distribution and distortion of the two profiles is reported and analyzed. AA6082 alloy was used as deforming material while H-13 hot-work tool steel was selected as die material. The experiments were repeated at least three times in the same conditions in order to achieve a statistical distribution of the acquired data: such data are then used as a reference for the 2009 edition of the extrusion benchmark.

Increased Productivity in Hot Aluminum Extrusion by Using Extrusion Dies with Inner Cooling Channels Manufactured by Rapid Tooling

2014 ◽  
Vol 611-612 ◽  
pp. 981-988 ◽  
Author(s):  
Ramona Hölker ◽  
Matthias Haase ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Surface Defects ◽  
Experimental Investigations ◽  
Extrusion Force ◽  
Aluminum Extrusion ◽  
Thermally Induced ◽  
Manufacturing Method ◽  
Cooling Channels ◽  
Extrusion Dies ◽  
Exit Temperature ◽  
Tooling Technology

The influence of local inner die cooling on the heat balance in hot aluminum extrusion was investigated. For the manufacturing of the die with cooling channels close to the forming zone, the layer-laminated manufacturing method was applied. The new tooling technology was applied in order to decrease the profiles exit temperature and to avoid thermally induced surface defects with the aim to raise the productivity in hot aluminum extrusion processes. Numerical and experimental investigations revealed that, while maintaining the exit temperature of the extrudate, a distinct increase of the production speed up to 300% can be realized, while the extrusion force increases only slightly. An effect on the profiles microstructure was also detected. By applying die cooling, grain coarsening can be significantly limited or even be avoided.

New Concepts for Cooling of Extrusion Dies Manufactured by Rapid Tooling

2011 ◽  
Vol 491 ◽  
pp. 223-232 ◽  
Author(s):  
Ramona Hölker ◽  
Andreas Jäger ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Rapid Tooling ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Workpiece Material ◽  
Cooling Channels ◽  
Extrusion Dies ◽  
Local Overheating ◽  
New Concepts ◽  
Die Surface ◽  
Manufacturing Technologies

To prevent local overheating of the workpiece material in hot aluminum extrusion the influence of die cooling was investigated. Numerical simulations of extrusion revealed an advantage of the die bearing cooling, which can be accomplished by locating the cooling channels close to the die/bearing surface. Since the fabrication of especially geometric complex cooling channels located near the die surface is not possible by conventional manufacturing technologies, the technology of rapid tooling was introduced into hot aluminum extrusion and experimentally tested. Cooling channels near to the bearings show promising results allowing extensions of extrusion limits, especially the extrusion speed and therefore productivity.

Application of Appropriate Coatings on Extrusion Dies and Evaluation of Their Performance During Hot Extrusion of Aluminum

2010 ◽  
Author(s):  
Antonios Lontos ◽  
George Demosthenous ◽  
Filippos Soukatzidis
Keyword(s):  
Hot Extrusion ◽  
Experimental Tests ◽  
Working Life ◽  
Element Model ◽  
Extrusion Process ◽  
Extrusion Speed ◽  
Coating Materials ◽  
Extrusion Dies ◽  
Billet Material ◽  
Aluminum Material

The aim of this paper is to study the effect of extrusion parameters (extrusion speed and temperature), die geometry, and the application of appropriate coating materials on the extrusion dies in order to extend their working life. To achieve the above goal FEM techniques and experimental tests adopted and simulating and experimental results evaluated. In this way, special FEM software was used to set up the finite element model of the aluminum extrusion. As a billet material the 6061 aluminum was used, with a specific diameter and length. The extrusion process was modeled as isothermal, which means that the billet material preheated at the specific temperature and then it was pressured into the two different dies, with a specific extrusion ratio. The extrusion speed was varied between 0.5 to 1 mm/sec and the extrusion temperature varied between 400 °C to 500 °C. The extrusion angle of the two different dies was 9° degrees. The fillet radius at the top surfaces was selected to be 1 mm. The friction between aluminum material (billet) and the extrusion equipment was i) aluminum material and die 0.3, ii) aluminum material and ram 0.9 and iii) aluminum material and container equal to 0.96. Optimized algorithms of extrusion parameters were proposed regarding to the concluded simulating results. The results obtain from the simulation procedure help to the better understanding of the specific extrusion process, leading to better modification of the experimental procedure. In this way, experimental tests were conducted on special laboratory extrusion press using the two different die geometries coated with three different PVD coatings. By means of these experimental tests the additional working life of the coated dies, during hot extrusion process, was able to be evaluated. In addition, the three different coatings where tested by established quality procedures in order to determine their behavior on the material of the extrusion die.

Experimental and Numerical Analysis of the Friction Condition in the Die Bearing during Aluminum Extrusion

2011 ◽  
Vol 491 ◽  
pp. 113-119 ◽  
Author(s):  
Sören Müller ◽  
Jerome Muehlhause ◽  
J. Maier ◽  
Pavel Hora
Keyword(s):  
Fem Simulation ◽  
Extrusion Process ◽  
Friction Model ◽  
Friction Condition ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Die Geometry ◽  
Various Boundary Conditions ◽  
Strain And Strain Rate ◽  
Realistic Representation

Of the various boundary conditions that are relevant for the correct modeling of the extrusion process the realistic representation of the friction in the die is important since it has a significant influence on the profile temperature, the strain and strain rate distribution in the die. In order to investigate the influence of the die geometry, respectively the geometry of the die bearing, a four-hole die with exchangeable inserts was designed. Thereby each of the four inserts was equipped with a thermocouple to record the profile temperature at the die bearing. Through the combination of different die bearing geometries (cylindrical, 0.5° closing, 1° closing, 0.5° opening) in the same die the influence on the extrusion speed and profile temperature could be evaluated with the exact same extrusion conditions. The observed differences in the temperature and speed in respect to the geometry of the die bearing where evaluated and implemented in a FEM simulation in order to validate the underlying friction model.

Studies on Process Parameters for Aluminum Extrusion of Slide Rails

2013 ◽  
Vol 467 ◽  
pp. 392-397 ◽  
Author(s):  
Shun Yu Shao ◽  
Wen Yen Wang ◽  
Yi An Chen
Keyword(s):  
Aluminum Alloy ◽  
Process Design ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Roll Forming ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Extrusion Die ◽  
Simulation Results ◽  
Product Weight

Slide rails are usually fabricated by roll forming and are used in kitchenware and cabinets mostly. However the product weight of slide rails is increased because larger dimensions are required to bear larger load when they are used in dies and warehouses. International suppliers start to develop Aluminum slide rails to decrease the product weight in recent years. The manufacturing and functional feasibility of Aluminum slide rail were discussed in this study. The Aluminum slide rail was designed according to ready-made slide rail, and the aluminum alloy was selected with required mechanical properties. The suitable extrusion die was designed and direct extrusion parameters of extrusion ratio, extrusion temperature, extrusion speed and extrusion load are also considered. The extrusion process of aluminum alloy was simulated by CAE software to check the mold and process design. The extrusion part of aluminum slide rail was carried out by extruder to verify the simulation results.

Modeling of Aluminum Extrusion Process Using Non-Orthogonal Block Structured Grids Based FVM

2011 ◽  
Vol 189-193 ◽  
pp. 1749-1752
Author(s):  
Rui Wang ◽  
Hong Zhong Li
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Special Treatment ◽  
Aluminum Extrusion ◽  
Rigid Plastic ◽  
Structured Grids ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Die Extrusion

The mathematic model of 3D aluminum extrusion processes using finite volume method (FVM) was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Non-orthogonal structured grids were used to match complex geometric boundaries and local refinement of grids was also realized. The collocated arrangement is used to discretize the governing equations on non-orthogonal grids directly, pressure oscillations bring by this arrangement and error caused by grid’s non-orthogonality is eliminated by special treatment. A pocket die extrusion process was simulated using the program developed in this paper. The simulation results were also compared with that simulated by FEM software Deform in the same process, material and die conditions. The feasibility and efficiency of the mathematic model built in this paper was demonstrated by the simulation results and the comparison.

scholarly journals Measuring the Deformation of a Flat Die by Applying a Laser Beam on a Reflecting Surface

2009 ◽  
Vol 424 ◽  
pp. 197-204 ◽  
Author(s):  
W. Assaad ◽  
H.J.M. Geijselaers ◽  
K.E. Nilsen
Keyword(s):  
Finite Element ◽  
Laser Beam ◽  
Extrusion Process ◽  
Trial And Error ◽  
Element Calculation ◽  
Extrusion Dies ◽  
Cheap Method ◽  
Trial And Error Method ◽  
Reflecting Surface ◽  
Error Method

The design of extrusion dies depends on the experience of the designer. After the die has been manufactured, it is tested during an extrusion process and machined several times until it works properly. The die is designed by a trial and error method which is expensive interms of time consumption and the amount of scrap. Research is going on to replace the trial pressing with finite element simulations that concentrate on material and tool analysis. In order to validate the tool simulations, an experiment is required for measuring the deformation of the die. Measuring the deformation of the die is faced with two main obstacles: high temperature and little free space. To overcome these obstacles a method is tried, which works by applying a laser beam on a reflecting surface. This cheap method is simple, robust and gives good results. This paper describes measuring the deformation of a flat die used to extrude a single U shape profile. In addition, finite element calculation of the die is performed. Finally, a comparison is performed between experimental and numerical results.

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