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.

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.

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.

An Analysis on the Forming Characteristics of AA 6063 Aluminium Alloy in Radial-Forward Extrusion Process

2006 ◽  
Vol 519-521 ◽  
pp. 925-930 ◽  
Author(s):  
G.M. Lee ◽  
H.S. Koo ◽  
H.J. Choi ◽  
Beong Bok Hwang
Keyword(s):  
Extrusion Process ◽  
Maximum Force ◽  
Deformation Pattern ◽  
Force Requirement ◽  
Forward Extrusion ◽  
Corner Radius ◽  
Forming Characteristics ◽  
Frictional Condition ◽  
Simulation Results ◽  
Design Factors

In this paper, the forming process of a central hub by radial-forward extrusion has been analyzed by the rigid-plastic finite element method. In this process, the material flows in radial direction and then deflects 90 degrees into the same direction as that of punch movement. Radial extrusion is used to produce parts that generally feature a central hub with radial protrusions. Design factors such as mandrel diameter, punch nose radius, deflection corner radius, gap width in annular direction, and frictional conditions are applied to the present study by simulation. AA 6063 aluminum alloy is selected as a model material for analysis in the present study. The influence of these design factors on the force requirement during the forming operation and the pressure exerted on the tooling such as the punch and mandrel is investigated and the simulation results are quantitatively summarized in terms of pressure distribution, force-stroke relationships, and maximum force requirement, respectively. The main goal of this study is to investigate the effect of those process parameters on the deformation pattern in radial-forward extrusion process, especially the effect of deflection corner radius. It has been concluded from the simulation results that a) the frictional condition between workpiece and tool does not affect the punch load very much, but the load supported by mandrel is more or less significantly influenced by the frictional condition compared to that of punch, b) the deflection corner radius turns out to be a major process parameter in terms of maximum force requirement, and c) a similar trend is found in the punch and mandrel forces during the radial 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.

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.

Deformation Analysis of Co-Extrusion Process of Aluminum Alloy and Copper Alloy

2007 ◽  
Vol 340-341 ◽  
pp. 645-648 ◽  
Author(s):  
Dong Hwan Jang ◽  
Beong Bok Hwang
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloy ◽  
Material Selection ◽  
Extrusion Process ◽  
Core Material ◽  
Deformation Pattern ◽  
Hard Material ◽  
Bonding Condition ◽  
Plastic Zones ◽  
Simulation Results

This paper is concerned with the analysis of plastic deformation of bimetal co-extrusion process. Extrusion is related to large deformation of material and leads to non-homogeneous deformation within work-piece material. The mechanism of plastic deformation during the composite rod extrusion is much more complicated than that in single metal extrusion. Deformation patterns of co-extrusion of two different materials are characterized by several process parameters. In this paper, the analysis is focused to investigate the effect of contact conditions along the interface between two different materials. The rigid-plastic finite element method was applied to the analysis of co-extrusion process. The selected materials are AA 1100 aluminum alloy as hard material and CDA 110 as soft one. This type of material selection was to examine the effect of hard core and soft sleeve and vice versa in terms of deformation pattern. The initial composite billets were prepared by inserting the core material in tight (0.023mm) and weak (0.012mm) interference bonding, respectively. Four different cases of co-extrusion process in terms of material combination and interference bonding were simulated to investigate the effect of material arrangement between core and sleeve, and of bonding on the plastic zones. It is concluded from the simulation results that the plastic zones in this co-extrusion process are not influenced much by the selection of material arrangements or bonding condition between construction materials. However, it was seen from the simulation results that the extrusion ratio of each construction material, i.e. homogeneity of co-extrusion, depends much on the material arrangement and the bonding condition.

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.

Simulation Analysis and Optimization of Lubricating Oil System

2021 ◽  
Author(s):  
Qiongxiao Wu ◽  
Jianjun Wang ◽  
Jingming Chen ◽  
Pengzheng Li
Keyword(s):  
Simulation Model ◽  
Simulation Analysis ◽  
Sudden Change ◽  
Pressure Change ◽  
Lubricating Oil ◽  
Maximum Pressure ◽  
Closing Time ◽  
Original Design ◽  
Relief Valve ◽  
Simulation Results

Abstract Based on the one-dimensional simulation model of lubricating oil system is established and analyzed by using FLOWMASTER software, this paper proposes a new method of optimizing lubricating oil system by PID technology. Ensure that the configuration requirements and control strategies of the relevant accessories of the simulation model are satisfied with the design requirements. Firstly, by simulating lubricating oil pressure fluctuation and lubricating oil flow distribution under Open/Close Valve in different opening and closing time, the optimal opening/closing time of Open/Close Valve is determined to be 0.2 s and 0.5 s respectively. Secondly, by writing the controller script file combined with a controller to realize automatic unloading relief valve simulation, determine the relief valve pressure regulating range of 0∼0.38 MPa, For precision of constant pressure valve of oil spill, the simulation results show that the average 10 m3/h flow caused by pressure changes of about 0.06 MPa. Under the flow sudden change signal of about 40 m3/h, the maximum pressure change is less than 0.1 MPa. Through the simulation results, it is found that most of the lubrication parts in the original design have the phenomenon of flow redundancy, which causes unnecessary pump power loss. The system is optimized by PID technology. By comparing the simulation results before and after optimization, it is found that the speed of constant displacement pump could be changed in time by PID controller, and the flow redundancy could be improved significantly, so the lubricating oil system could be lower consumption and achieve the purpose of optimization.

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