The Influence of Die Geometry on the Radial Extrusion Processes with AA 6063 Aluminium Alloy

2006 ◽  
Vol 519-521 ◽  
pp. 937-942
Author(s):  
Dong Hwan Jang ◽  
J.H. Ok ◽  
H.S. Koo ◽  
G.M. Lee ◽  
Beong Bok Hwang
Keyword(s):  
Process Parameters ◽  
Material Flow ◽  
Deformation Pattern ◽  
Relative Deformation ◽  
Die Geometry ◽  
Single Action ◽  
Pressing Process ◽  
Major Process ◽  
Forming Characteristics ◽  
Gap Height

The rigid-plastic finite element method has been applied to three variants of radial extrusion processes to investigate the influence of die geometry on the material flow into the flange gap. Case I involves forcing a cylindrical billet against a flat die, which is a single action pressing process. In case II, another single action pressing process, the upper punch forces a billet against a stationary punch recessed in the lower die. Both the upper and lower punches move together in Case III toward the center of billet at the same speed with a double action tool. Major process parameters are identified as the relative gap height and the die corner radius in constant relative deformation. The relative gap height is defined as the ratio of gap height to billet diameter. Extensive simulation work for various combinations of process parameter value has been performed and then the main characteristics of the deformation patterns of each case are observed to define the terms which represent the forming characteristics of the flange in radial extrusion processes in terms of separation height, asymmetric ratio of height, and asymmetric ratio of angle, respectively. The effect of major process parameters on the material flow into the flange gap has been also analyzed in terms of flange radius and flange angle. The effect of frictional condition on the separation height has been also analyzed to investigate the edge separation of flange from the flat die. AA 6063 aluminum alloy is selected as a model material throughout the analysis. Simple comparison between AA 6063 and AISI 1006 steel has been also made to investigate the effect of material selection on the deformation pattern, especially in terms of separation height in Case I and asymmetry in Case II, respectively.

Influence of Process Parameters on T-Shape Tube HydroForming Characteristics for Magnesium Alloy

2007 ◽  
Vol 364-366 ◽  
pp. 973-979
Author(s):  
Shen Yung Lin ◽  
C.M. Chang ◽  
C.K. Chang
Keyword(s):  
Magnesium Alloy ◽  
Strain Hardening ◽  
Process Parameters ◽  
Material Flow ◽  
Large Strain ◽  
Manufacturing Cost ◽  
Hydraulic Pressure ◽  
Influence Of Process Parameters ◽  
Forming Characteristics ◽  
Strain Hardening Rate

Due to the light weight and electromagnetic interference shielding capabilities in magnesium alloy material, it is widely utilized in 3C electronic components and automobile parts. However, its formability is very poor due to the phenomenon of negative strain hardening rate appearing as the deformation in large strain range, so it is usually formed as die casting or casting styles leads to much scrap, and manufacturing cost is thus increased. The objective of this study is to investigate the effect of process parameters on T-shape tube hydro-forming characteristics for magnesium alloy and it may offer the data resulting from the analysis to predict an acceptable product of tube fitting for magnesium alloy forming in industry. AZ31 magnesium alloy tube is used as the billet material for hydro-forming with hydraulic pressure as the main forming power combined with the mechanical auxiliary force from the punch to fabricate the T-shape tubing products. Finite element code DEFORM-3D is adopted to investigate the forming states of T-shape tube forming, by changing process parameters; such as punch velocity, hydraulic pressure, fillet radius of the die and tool-workpiece interface friction etc. to investigate the material flow of tube fitting, wall thickness variations, and stress and strain distributions. By qualifying the forming processes whether if it is completed or not, and synthesizing the overall analysis and judgment, we establish an admissible level of process parameter range for complete tube manufacture. The results show that suitable mechanical force can help material flow, prevent large strain deformation falling into the area of negative strain hardening rate, enhance magnesium alloy to become easy in forming and make tube fitting to be formed successfully.

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.

Prediction of Surface Profile in Friction Stir Welding Using Coupled Eulerian and Lagrangian Method

2020 ◽  
Author(s):  
Debtanay Das ◽  
Swarup Bag ◽  
Sukhomay Pal ◽  
M. Ruhul Amin
Keyword(s):  
Friction Stir Welding ◽  
Surface Morphology ◽  
Process Parameters ◽  
Chip Formation ◽  
Material Flow ◽  
Defect Formation ◽  
Current Model ◽  
Surface Profile ◽  
Green Technology ◽  
Friction Stir

Abstract Friction stir welding (FSW) is widely accepted by industry because of multiple advantages such as low-temperature process, green technology, and capable of producing good quality weld joints. Extensive research has been conducted to understand the physical process and material flow during FSW. The published works mainly discussed the effects of various process parameters on temperature distribution and microstructure formation. There are few works on the prediction of defect formation from a physics-based model. However, these models ignore chip formation or surface morphology and material loss during the FSW process. In the present work, a fully coupled 3D thermo-mechanical model is developed to predict the chip formation and surface morphology during welding. The effects of various process parameters on surface morphology are also studied using the current model. Coupled Eulerian-Lagrangian (CEL) technique is used to model the FSW process using a commercial software ABAQUS. The model is validated by comparing the results in published literature. The current model is capable of predicting the material flow out of the workpiece and thus enables the visualization of the chip formation. The developed model can extensively be used to predict the surface quality of the friction stir welded joints.

Experimental Research of Electrochemical Mechanical Polishing (ECMP) for Micro Tool Electrode

2011 ◽  
Vol 314-316 ◽  
pp. 1846-1850 ◽  
Author(s):  
Shuai Guo ◽  
Z.N Guo ◽  
Hong Ping Luo ◽  
Wen Cai Gu
Keyword(s):  
Experimental Research ◽  
Process Parameters ◽  
Mechanical Polishing ◽  
Working Fluid ◽  
Tool Electrode ◽  
Electrical Parameters ◽  
Electrochemical Mechanical Polishing ◽  
Major Process ◽  
Micro Tool ◽  
Quantitative Analyses

The mechanism of the elctrochemical mechanical polishing (ECMP) technology for micro tool electrode was investigated. In this paper, suitable major process parameters on the surface quality were evaluated, the major parameters contains electrical parameters, machining gap, the working fluid and other factors. In quantitative analyses, the process of the ECMP technology were conducted. The roughness of the workpiece was reduced from a relatively high value to a mirror effect.

Upper Bound Solutions to Plane-Strain Extrusion Problems

1970 ◽  
Vol 92 (1) ◽  
pp. 158-164 ◽  
Author(s):  
P. C. T. Chen
Keyword(s):  
Plane Strain ◽  
Upper Bound ◽  
Material Properties ◽  
Incompressible Material ◽  
Velocity Fields ◽  
Deformation Pattern ◽  
Upper Bound Theorem ◽  
Admissible Velocity ◽  
Die Geometry ◽  
Bound Theorem

A method for selecting admissible velocity fields is presented for incompressible material. As illustrations, extrusion processes through three basic types of curved dies have been treated: cosine, elliptic, and hyperbolic. Upper-bound theorem is used in obtaining mean extrusion pressures and also in choosing the most suitable deformation pattern for extrusion through square dies. Effects of die geometry, friction, and material properties are discussed.

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.

Sign in / Sign up

Export Citation Format

Share Document