Numerical Analysis on the Extruded Volume and Length Ratios of Backward Tube to Forward Rod in Combined Extrusion Processes

2006 ◽  
Vol 519-521 ◽  
pp. 919-924 ◽  
Author(s):  
B.S. Ham ◽  
J.H. Ok ◽  
Jung Min Seo ◽  
Beong Bok Hwang ◽  
K.H. Min ◽  
...  
Keyword(s):  
Process Parameters ◽  
Material Flow ◽  
Volume Ratio ◽  
Forward Direction ◽  
Extrusion Process ◽  
Forming Load ◽  
Tube Extrusion ◽  
Corner Radius ◽  
Combined Operation ◽  
Simulation Results

This paper is concerned with forward rod extrusion combined simultaneously with backward tube extrusion process in both steady and transient states. The analysis has been conducted in numerical manner by employing a rigid-plastic finite element method. AA 2024 aluminum alloy was selected as a model material for analysis. Among many process parameters, major design factors chosen for analysis include frictional condition, thickness of tube in backward direction, punch corner radius, and die corner radius. The main goal of this study is to investigate the material flow characteristics in combined extrusion process, i.e. forward rod extrusion combined simultaneously with backward tube extrusion process. Simulation results have been summarized in term of relationships between process parameters and extruded length and volume ratios, and between process parameters and force requirements, respectively. The extruded length ratio is defined as the ratio of tube length extruded in backward direction to rod length extruded in forward direction, and the volume ratio as that of extruded volume in backward direction to that in forward direction, respectively. It has been revealed from the simulation results that material flow into both backward and forward directions are mostly influenced by the backward tube thickness, and other process parameters such as die corner radius etc. have little influence on the volume ratio particularly in steady state of combined extrusion process. The pressure distributions along the tool-workpiece interface have been also analyzed such that the pressure exerted on die is not so significant in this particular process such as combined operation process. Comparisons between multi-stage forming process in sequence operation and one stage combined operation have been also made in terms of forming load and pressure exerted on die. The simulation results shows that the combined extrusion process has the greatest advantage of lower forming load comparing to that in sequence operation.

An Analysis on the Force Requirement of Combined Operations for Forward and Backward Tube Forming

2006 ◽  
Vol 519-521 ◽  
pp. 943-948
Author(s):  
Beong Bok Hwang ◽  
G.M. Lee ◽  
Y.H. Lee ◽  
J.H. Ok ◽  
S.H. Kim
Keyword(s):  
Process Parameters ◽  
Extrusion Process ◽  
Thickness Ratio ◽  
Maximum Pressure ◽  
Deformation Pattern ◽  
Force Requirement ◽  
Forming Load ◽  
Tube Extrusion ◽  
Corner Radius ◽  
Simulation Results

In the present study, the finite element analysis has been conducted to investigate the deformation characteristics of forward and backward can extrusion process using AA 1100 aluminum alloy tubes in terms of maximum forming load and extruded length ratio in a combined material flow. A commercially available code is used to conduct rigid-plastic FEM simulation. Hollow tubes are selected as initial billets and the punch geometries follow the recommendation of ICFG. Selected design parametrs involved in simulation includes punch nose radius, die corner radius, frictional condition, and punch face angle. The investigation is foucused on the analysis of deformation pattern and its characteristics in a forward tube extrusion combined simultaneously with backward tube extrusion process main in terms of force requirements for this operation according to various punch nose radii and backward tube thickness. The simulation results are summarized in terms of load-stroke relationships for different process parameters such as backward tube thickness, die corner radii, and punch face angle, respectively, and pressure distributions exerted on die, and comparison of die pressure and forming load between combined extrusion and two stage extrusion process in sequencial operation. Extensive analyses are also made to investigate the relationships between process parameters and extruded lengths in both forward and backward directions. It has been concluded from simulation results that a) the combined operation is superior to multi-stage extrusion process in sequential operation in terms of maximum forming load and maximum pressure exerted on die, b) the length of forward extruded tube increases and that of backward extruded tube decreases as the thickness ratio decreases, and c) the forming load is influenced much by the thickness ratio and the other design factors such as die corner radius and punch face angle does not affect much on the force requirement for the combined extrusion process.

The Forming Characteristics of AA 2024 Aluminium Alloy in Radial Extrusion Process Combined with Backward Extrusion

2006 ◽  
Vol 519-521 ◽  
pp. 955-960 ◽  
Author(s):  
Dong Hwan Jang ◽  
J.H. Ok ◽  
G.M. Lee ◽  
Beong Bok Hwang
Keyword(s):  
Material Flow ◽  
Volume Ratio ◽  
Extrusion Process ◽  
Process Conditions ◽  
Forming Load ◽  
Backward Extrusion ◽  
Aa 2024 ◽  
Forming Characteristics ◽  
Frictional Condition ◽  
Simulation Results

Numerical analysis of radial extrusion process combined with backward extrusion has been performed to investigate the forming characteristics of an aluminum alloy in a combined extrusion process. Various variables such as gap size, die corner radius and frictional conditions are adopted as design or process parameters for analysis in this paper. The main investigation is focused on the analysis of forming characteristics of AA 2024 aluminum alloy in terms of material flow into backward can and radial flange sections. Due to various die geometries and process conditions such as frictional conditions, the material flow into a can and flange shows different patterns during the combined extrusion process and its characteristics are well summarized quantitatively in this paper in terms of forming load, volume ratio etc. Extensive simulation work leads to quantitative relationships between process conditions and the forming characteristics such as volume ratio of flange to can and the size of can and flange in terms of the can height extruded backward. It is easily seen from the simulation results that the volume ratio, which is defined as the ratio of flange volume to can volume, increases as the gap size and/or die corner radius increase. However, it is interesting to note that the frictional condition has little influence on the forming load and the deformation patterns. Usually, the frictional condition is a greatest process variable in normal forging operation. It might be believed from the simulation results that the frictional conditions are not a major process parameter in case of combined extrusion processes. It is also found that the can size, which is defined as the height of billet after forming, turns out to be even smaller than that of initial billet under a certain condition of die geometry.

Forming Load Characteristics of Forward and Backward Tube Extrusion Process in Combined Operation

2007 ◽  
Vol 340-341 ◽  
pp. 649-654 ◽  
Author(s):  
Jung Min Seo ◽  
Dong Hwan Jang ◽  
K.H. Min ◽  
H.S. Koo ◽  
S.H. Kim ◽  
...  
Keyword(s):  
Process Parameters ◽  
Extrusion Process ◽  
Nose Radius ◽  
Forming Load ◽  
Tube Extrusion ◽  
Initial Billet ◽  
Minimum Deformation ◽  
Load Characteristics ◽  
Simulation Results ◽  
Punch Geometry

Combined extrusion processes generally have advantages of forming in terms of the minimum deformation power since the material is pressed through two or more orifices simultaneously. This paper is concerned with the analysis of forming load characteristics of a forward-backward can extrusion process using thick-walled pipe as an initial billet. The combined tube extrusion process was analyzed by using a commercial finite element code. A thick-walled pipe was selected as an initial billet and the punch geometry has been chosen on the basis of ICFG recommendation. Several tool and process parameters were employed in this analysis and they are punch nose radius, backward tube thickness, punch face angle, and frictional conditions, respectively. The main purpose of this study is to investigate the effect of process parameters on the force requirements in combined extrusion process. The possible extrusion process to form a forward-backward tube parts in different process sequences were also simulated to investigate the force requirements in sequential operations, i.e. separate operations. It was easily concluded from the simulation results that lower forming load was predicted for the combined extrusion, compared to those for separate sequential operations. It was also revealed that the punch nose radius and the punch face angle have little effect on the force requirements and the forming load increases significantly as the frictional condition along tool-workpiece interface becomes severe. The simulation results in this study suggest that the combined extrusion process has strong advantage in terms of force requirements as long as the simultaneous material flow into multiple orifices could be closely controlled.

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.

An Analysis on the Forming Load of AA 2024 Aluminium Alloy in Combined and Sequence Operation Process

2006 ◽  
Vol 519-521 ◽  
pp. 949-954 ◽  
Author(s):  
Beong Bok Hwang ◽  
J.H. Shim ◽  
Jung Min Seo ◽  
H.S. Koo ◽  
J.H. Ok ◽  
...  
Keyword(s):  
Finite Element ◽  
Load Capacity ◽  
Low Cost ◽  
Forming Load ◽  
Mechanical Press ◽  
Combined Operation ◽  
Aa 2024 ◽  
Load Characteristics ◽  
Simulation Results ◽  
Selection Of

This paper is concerned with the analysis of the forming load characteristics of a forward-backward can extrusion in both combined and sequence operation. A commercially available finite element program, which is coded in the rigid-plastic finite element method, has been employed to investigate the forming load characteristics. AA 2024 aluminum alloy is selected as a model material. The analysis in the present study is extended to the selection of press frame capacity for producing efficiently final product at low cost. The possible extrusion processes to shape a forward-backward can component with different outer diameters are categorized to estimate quantitatively the force requirement for forming forward-backward can part, forming energy, and maximum pressure exerted on the die-material interfaces, respectively. The categorized processes are composed of combined and/or some basic extrusion processes such as sequence operation. Based on the simulation results about forming load characteristics, the frame capacity of a mechanical press of crank-drive type suitable for a selected process could be determined along with securing the load capacity and with considering productivity. In addition, it is suggested that different load capacities be selected for different dimensions of a part such as wall thickness in forward direction and etc. It is concluded quantitatively from the simulation results that the combined operation is superior to sequence operation in terms of relatively low forming load and thus it leads to low cost for forming equipments. However, it is also known from the simulation results that the precise control of dimensional accuracy is not so easy in combined operation. The results in this paper could be a good reference for analysis of forming process for complex parts and selection of proper frame capacity of a mechanical press to achieve low production cost and thus high productivity.

Improved Extrudability of High Strength Alloys Using an Optimization Method Based on a Combination of Experiments and FEM Software

2013 ◽  
Vol 585 ◽  
pp. 165-171 ◽  
Author(s):  
Stanka Tomovic-Petrovic ◽  
Rune Østhus ◽  
Ola Jensrud
Keyword(s):  
Material Flow ◽  
Silicon Content ◽  
High Strength ◽  
Optimization Method ◽  
Extrusion Process ◽  
Model Alloy ◽  
Process Variables ◽  
Die Geometry ◽  
Simulation Results ◽  
6Xxx Series

Numerical analysis of the material flow during the extrusion process for high alloyed variants of the AA 6xxx series is presented in this paper. The analysis was performed by using the commercial FE code Forge2011®. Another issue considered in the paper was an interrelation between the die geometry and the critical extrusion process variables. For optimization of the die exit geometry, the model was produced with the use of linked equation in SolidWorks® combined with Mode FRONTIER. Several extrusion trials were performed to provide a basis for the verification of simulation results as extrusion temperature, speed and force. For the purpose, rods of a model alloy designated as AlMgSi4, based on an industrial AA6082 aluminium alloy with significantly higher silicon content, were extruded. A good correlation between measured and calculated results was obtained. This approach may enable simplifying when dealing with design of a new alloy.

Numerical Simulation of the Extrusion Process with Feeder Plate Die

2014 ◽  
Vol 926-930 ◽  
pp. 3521-3526
Author(s):  
Tian Xiao Chen ◽  
Chun Mei Li ◽  
Nan Pu Cheng ◽  
Hui Na Jia
Keyword(s):  
Numerical Simulation ◽  
Material Flow ◽  
Strain Distribution ◽  
Extrusion Process ◽  
Geometric Parameters ◽  
Geometrical Parameters ◽  
Direct Extrusion ◽  
Axial Hole ◽  
Hole Defect ◽  
Simulation Results

The direct extrusion process by using a newly designed die with different angle and feeder plate numbers has been simulated to systematically investigate the effects of different geometric parameters angle and feeder plate number on the strain distribution, the load and the axial hole defect. The simulation results show that the extrusion process with multiple feeder plate die is similar to that of the extrusion for many times. The angle and feeder plate make the material flow more fluently and ameliorate the axial hole defect. The larger angle reduces the load while the feeder plate increases it. Suitable geometrical parameters can significantly enhance strain in workpiece.

Anti-Extrusion Process in the Performance of Different Parameters on the Analysis of Metals

2011 ◽  
Vol 337 ◽  
pp. 456-459 ◽  
Author(s):  
Han Dong Zhao ◽  
Hua Zhang ◽  
Peng Sun ◽  
Fei Li
Keyword(s):  
Process Parameters ◽  
Metal Forming ◽  
Metal Flow ◽  
Extrusion Process ◽  
Flow Speed ◽  
Simulation Results ◽  
Pressure Changes

This paper mainly introduces metal forming on extrusion simulations. Different process parameters of the simulation results are analyzed, such as ingots by billet pressure changes, change of temperature, metal flow speed of different process, and the metal performance changes caused by them are discussed.

An Analysis on the Surface Expansion of Aluminium Alloys in Backward Can Extrusion Process

2006 ◽  
Vol 519-521 ◽  
pp. 931-936 ◽  
Author(s):  
J.H. Ok ◽  
Beong Bok Hwang
Keyword(s):  
Aluminum Alloys ◽  
Material Flow ◽  
Extrusion Process ◽  
Process Conditions ◽  
Geometrical Parameters ◽  
Rigid Plastic ◽  
Geometrical Condition ◽  
Aa 2024 ◽  
Surface Expansion ◽  
Simulation Results

This paper is concerned with the analysis on the surface expansion of AA 2024 and AA 1100 aluminum alloys in backward extrusion process. Due to heavy surface expansion appeared usually in the backward can extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the surface expansion is analyzed especially under various process conditions. The main goal of this study is to investigate the influence of degree of reduction in height, geometries of punch nose, friction and hardening characteristics of different aluminum alloys on the material flow and thus on the surface expansion on the working material. Two different materials are selected for investigation as model materials and they are AA 2024 and AA 1100 aluminum alloys. The geometrical parameters employed in analysis include punch corner radius and punch face angle. The geometry of punch follows basically the recommendation of ICFG and some variations of punch geometry are adopted to obtain quantitative information on the effect of geometrical parameters on material flow. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward can extrusion process under different geometrical, material, and interface conditions. The simulation results are summarized in terms of surface expansion at different reduction in height, deformation patterns including pressure distributions along the interface between workpiece and punch, comparison of surface expansion between two model materials, geometrical and interfacial parametric effects on surface expansion, and load-stroke relationships. It has been concluded from the present study that the geometrical condition of punch is the most significant factor among the parameters employed in this study. It is also known from the simulation results that the difference in surface expansion according to different material properties is not more or less significant.

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