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.

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.

Study of Flow Balance and Temperature Evolution over Multiple Aluminum Extrusion Press Cycles with HyperXtrude 9.0

2009 ◽  
Vol 424 ◽  
pp. 257-264 ◽  
Author(s):  
Amin Farjad Bastani ◽  
Trond Aukrust ◽  
Inge Skauvik
Keyword(s):  
Finite Element ◽  
Finite Elements ◽  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Billet Temperature ◽  
Exit Velocity ◽  
Extrusion Press ◽  
Flow Balance ◽  
Exit Temperature ◽  
Ram Speed

In this research, transient finite element simulations of the aluminum extrusion process have been performed in order to study how process parameters influence flow balance and exit temperature. This has been achieved by investigating the influence of billet taper, front billet temperature and ram speed on the run-out velocity and temperature of two separate outlets. Analysis of variance (ANOVA) has been employed to study the effect of each parameter on the velocity and temperature variation of the extruded section. Results show that increasing each of these three parameters results in an undesired increase in exit velocity and temperature. The front billet temperature is found to be the most significant factor affecting the variation. The finite elements software used was Altair HyperXtrude 9.0.

Mechanical Failure Study of Aluminum Extrusion Dies as Affected by the Quality of the Billets

2014 ◽  
Vol 42 (4) ◽  
pp. 20120291
Author(s):  
Shadi Al Khateeb ◽  
Amin Al robaidi ◽  
Radwan Dweiri ◽  
Ahmad Lebzo ◽  
Mahmood Al-Sawa'adeh
Keyword(s):  
Mechanical Failure ◽  
Aluminum Extrusion ◽  
Extrusion Dies

Study of the Size Effect on Friction Conditions in Microextrusion—Part I: Microextrusion Experiments and Analysis

2006 ◽  
Vol 129 (4) ◽  
pp. 669-676 ◽  
Author(s):  
Neil Krishnan ◽  
Jian Cao ◽  
Kuniaki Dohda
Keyword(s):  
Size Effects ◽  
Circular Cross Section ◽  
High Strength ◽  
Analytical Models ◽  
Homogeneous Material ◽  
Experimental Setup ◽  
Extrusion Force ◽  
Frictional Behavior ◽  
Extrusion Dies ◽  
Metallic Parts

Microforming is a relatively new realm of manufacturing technology that addresses the issues involved in the fabrication of metallic microparts, i.e., metallic parts that have at least two characteristic dimensions in the sub-millimeter range. The recent trend towards miniaturization of products and technology has produced a strong demand for such metallic microparts with extremely small geometric features and high tolerances. Conventional forming technologies, such as extrusion, have encountered new challenges at the microscale due to the influence of “size effects” that tend to be predominant at this length scale. One of the factors that of interest is friction. The two companion papers investigate the frictional behavior and size effects observed during microextrusion in Part I and in a stored-energy Kolsky bar test in Part II. In this first paper, a novel experimental setup consisting of forming assembly and a loading stage has been developed to obtain the force-displacement response for the extrusion of pins made of brass (Cu∕Zn: 70∕30). This experimental setup is used to extrude pins with a circular cross section that have a final extruded diameter ranging from 1.33mm down to 570μm. The experimental results are then compared to finite-element simulations and analytical models to quantify the frictional behavior. It was found that the friction condition was nonuniform and showed a dependence on the dimensions (or size) of the micropin under the assumption of a homogeneous material deformation. Such assumption will be eliminated in Part II where the friction coefficient is more directly measured. Part I also investigates the validity of using high-strength/low-friction die coatings to improve the tribological characteristics observed in micro-extrusion. Three different extrusion dies coated with diamondlike carbon with silicon (DLC-Si), chromium nitride (CrN), and titanium nitride (TiN) were used in the microextrusion experiments. All the coatings worked satisfactorily in reducing the friction and, correspondingly, the extrusion force with the DLC-Si coating producing the best results.

Fatigue Fracture Investigation of Cemented Carbide Tools in Gear Hobbing, Part 2: The Effect of Cutting Parameters on the Level of Tool Stresses—A Quantitative Parametric Analysis

2002 ◽  
Vol 124 (4) ◽  
pp. 792-798 ◽  
Author(s):  
A. Antoniadis ◽  
N. Vidakis ◽  
N. Bilalis
Keyword(s):  
Parametric Analysis ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Experimental Investigations ◽  
Tool Geometry ◽  
Technological Parameters ◽  
Manufacturing Method ◽  
Gear Hobbing ◽  
Cemented Carbide Tools ◽  
Selection Of

Gear Hobbing is a complex gear manufacturing method, possessing great industrial significance. The convoluted geometry of the cutting tools brings on modeling problems and is the main reason for the almost exclusive application of HSS as cutting material. However, despite its complicated kinematics, gear hobbing is sufficiently described by well-established software tools, which were presented in the first part of the present paper. Experimental investigations exhibited the cutting performance of cemented carbide cutting teeth, which were expected to be potential alternatives for massive hob production. In these cutting experiments, hardmetal tools exhibited in several cases early and unexpected brittle failures, which were interpreted by the FRSFEM model in the first part of the paper. This analysis indicated that the occurring dynamic stresses are the reason for the observed fatigue failures on the cemented carbide tools. The occurring stresses are highly dependent on the selection of cutting parameters and on the tool geometry. Therefore, the proper selection of the cutting data may prevent the early tool failures, as the dominant parameters for tool wear, allowing it to be worn out by the conventional abrasive mechanisms. Thus, the doubtless dominance of cemented carbide over the HSS tools, may be rendered. The present work illustrates a parametric analysis, which describes quantitatively the effect of various cutting and technological parameters on the stress level occurring in gear hobbing, with cemented carbide cutting teeth. Hereby, the optimization of the tool life is enabled, allowing the maximum exploitation of modern gear hobbing machine tools. Optimized gear hobbing with cemented carbide tools may be used, in order to introduce higher cutting speeds in massive gear production.

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