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.

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.

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.

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.

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.

Modeling and Simulation of Microstructure Evolution in Extruded Aluminum Profiles

2009 ◽  
Vol 424 ◽  
pp. 43-50
Author(s):  
Farhad Parvizian ◽  
T. Kayser ◽  
Bob Svendsen
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloys ◽  
Modeling And Simulation ◽  
Microstructure Evolution ◽  
Internal State ◽  
Extrusion Process ◽  
State Variables ◽  
Cooling Process ◽  
Microstructure Parameters ◽  
Simulation Results

The purpose of this work is to predict the microstructure evolution of aluminum alloys during hot metal forming processes using the Finite Element Method (FEM). Here, the focus will be on the extrusion process of aluminum alloys. Several micromechanical mechanisms such as diffusion, recovery, recrystallization and grain growth are involved in various subsequent stages of the extrusion and the cooling process afterward. The evolution of microstructure parameters is motivated by plastic deformation and temperature. A number of thermomechanical aspects such as plastic deformation, heat transfer between the material and the container, heat generated by friction, and cooling process after the extrusion are involved in the extrusion process and result in changes in temperature and microstructure parameters subsequently. Therefore a thermomechanically coupled modeling and simulation which includes all of these aspects is required for an accurate prediction of the microstructure evolution. A brief explanation of the isotropic thermoelastic viscoplastic material model including some of the simulation results of this model, which is implemented as a user material (UMAT) in the FEM software ABAQUS, will be given. The microstructure variables are thereby modeled as internal state variables. The simulation results are finally compared with some experimental results.

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.

An Investigation into Optimized Ti-6Al-4V Titanium Alloy Equal Channel Angular Extrusion Process

2013 ◽  
Vol 479-480 ◽  
pp. 181-186 ◽  
Author(s):  
Dyi Cheng Chen ◽  
Yi Ju Li ◽  
Gow Yi Tzou
Keyword(s):  
Plastic Deformation ◽  
Titanium Alloy ◽  
Deformation Behavior ◽  
Equal Channel Angular Extrusion ◽  
Extrusion Process ◽  
Process Conditions ◽  
Rigid Plastic ◽  
Die Geometry ◽  
Plastic Deformation Behavior ◽  
Internal Angle

The shear plastic deformation behavior of a material during equal channel angular (ECA) extrusion is governed primarily by the die geometry, the material properties, and the process conditions. This paper employs the rigid-plastic finite element (FE) to investigate the plastic deformation behavior of Ti-6Al-4V titanium alloy during ECA extrusion processing. Under various ECA extrusion conditions, the FE analysis investigates the damage factor distribution, the effective stress-strain distribution, and the die load at the exit. The relative influences of the internal angle between the two die channels, the friction factors, the titanium alloy temperature and the strain rate of billet are systematically examined. In addition, the Taguchi method is employed to optimize the ECA process parameters. The simulation results confirm the effectiveness of this robust design methodology in optimizing the ECA processing of the current Ti-6Al-4V titanium alloy.

Body Fitted Grids Based FVM Simulation of Aluminum Extrusion Process

2011 ◽  
Vol 418-420 ◽  
pp. 2102-2105
Author(s):  
Rui Wang
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Friction Model ◽  
Aluminum Extrusion ◽  
Local Refinement ◽  
Rigid Plastic ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Process Material

A body fitted based finite volume method (FVM) model of aluminum extrusion processes was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Body fitted grids were used to match complex geometric boundaries and local refinement of grids was also realized. Plastic shear friction model was applied on body fitted grids. A typical then walled profile 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.

Material Flow Characteristics on the Forward and Backward Solid Extrusion Process

2005 ◽  
Vol 475-479 ◽  
pp. 3071-3074 ◽  
Author(s):  
S.H. Kim ◽  
T.K. Ryu ◽  
Hyoung Jin Choi ◽  
H.S. Koo ◽  
Beong Bok Hwang
Keyword(s):  
Material Flow ◽  
Process Condition ◽  
Flow Characteristics ◽  
Volume Ratio ◽  
Extrusion Process ◽  
Design Parameters ◽  
Deformation Pattern ◽  
Outer Diameter ◽  
Rigid Plastic ◽  
Workpiece Material

FE simulations were carried out to analyze the influence of die geometry and process condition on the material flow. Deformation pattern and its characteristics in a combined forward and backward solid extrusion process were analyzed in terms of forming loads as the primary parameter, volume ratio of backward solid to forward solid and die pressure between tool-workpiece interfaces. Major parameter is the outer diameter ratio (ODR) of backward solid radius to forward solid radius with constant outer diameter of forward solid. Furthermore, extensive simulation works were conducted to investigate the effect of minor design parameters on stable material flow such as punch corner radius. The deformation pattern of material flow in a combined solid extrusion process is also presented. The results from the process simulation predict the flow modes of workpiece material and the die pressure occurring at the contact surface between workpiece and punch. The process of a combined forward and backward solid extrusion was analyzed using a rigid plastic finite element code to get information about the forming load and die pressure distribution, etc.

Sign in / Sign up

Export Citation Format

Share Document