scholarly journals MULTIPLE PROCESS PARAMETER OPTIMIZATION OF FORWARD EXTRUSION PROCESS ON AA 2024

2021 ◽  
Vol 13 (2) ◽  
pp. 63-75
Author(s):  
Anupama Francy Kothasiri ◽  
◽  
Srinivasa Rao Chalamalasetti ◽  
Gopalakrishnaiah Peteti ◽  
◽  
...  

Extrusion is a simple metal forming process in which a block of metal is forced through a die orifice with a certain shape under high pressure. This extrusion process is influenced by many process parameters such as die angle (DA), ram speed (RS), coefficient of friction (COF), Extrusion ratio, Die land height, work piece diameter and length, material properties etc. In extrusion process, extrusion force is crucial parameter, the flow of metal and hence the extrusion force is significantly influenced by the above parameters which results in quality of the product. The present study numerically investigates the influence of major process parameters such as die angle, ram speed, coefficient of friction on the extrusion process. The AA2024 material is chosen as work piece material and the extrusion force and damage is considered as the output responses. The input process parameters are varied in three levels (Level - 1: 10° DA, 1.6mm/min RS, 0.06 COF; Level - 2: 20° DA, 3.2mm/min RS, 0.08 COF; Level - 3: 30° DA, 4.8mm/min RS, 0.01 COF). Numerical simulations are performed by using DEFORM 3D software. The simulations are conducted as per L27 orthogonal array. From the results it is observed that Increase of die angle, ram speed and coefficient of friction increases the extrusion force. The die angle has highest (86.45%) influence on the extrusion force, then after ram speed (6.60%). The coefficient of friction has insignificant influence (0.55%). It is also noticed that the damage is considerable after the 20° die angle. A multi parameter optimization is also done by using the Grey relation analysis by considering the equal weightage of extrusion force and damage. The optimum levels of input process parameters for the minimum extrusion force and damage is DA level 1, RS level 1, and COF level 3.

2009 ◽  
Vol 16-19 ◽  
pp. 515-519
Author(s):  
Hua Xiang ◽  
Xin Cun Zhuang ◽  
Zhen Zhao

Extrusion force plays a significant role on sheet metal extrusion process. It is characterized by various process parameters including material properties, extrusion ratio, friction, tool shape etc. In this paper, a reasonable FEM model of sheet metal extrusion process was established and validated by comparing the results of simulation and experiment firstly. Based on the reliable model, the effect on extrusion force of various process parameters was investigated with orthogonal experimental design combined FEM simulation. The work presented in this paper has laid certain foundation for further work of modeling and optimizing extrusion force.


2020 ◽  
Vol 10 (22) ◽  
pp. 8048
Author(s):  
Daniel Fernández ◽  
Alvaro Rodríguez-Prieto ◽  
Ana María Camacho

This paper investigates the extrusion process to manufacture bimetallic cylinders combining a magnesium alloy core (AZ31B) and a titanium alloy sleeve (Ti6Al4V) of interest in aeronautical applications. A robust finite element model has been developed to determine the most influential parameters and to study the effect of them on the extrusion force and damage induced by means of Design of Experiments (DOE) and Taguchi method. The results show that the most influential parameters in the extrusion forces are the friction between sleeve and container/die and the height of the cylinder; and the less influential ones are the process temperature and ram speed. Moreover, minimum values of forces along with low damage can be reached by favorable interface contact conditions, minimizing the friction at the core-container/die interface, as the main influencing factor; followed by the geometrical dimensions of the billet, being the billet height more important when paying attention to the minimum forces, and being the core diameter when considering the minimum damage as the most important criterion. The results can potentially be used to improve the efficiency of this kind of extrusion process and the quality of the extruded part that, along with the use of lightweight materials, can contribute to sustainable production approaches.


Author(s):  
V. S. Senthil Kumar ◽  
U. Mohammed Iqbal

Twist extrusion is a severe plastic deformation in which the rectangular shaped work piece is extruded through a die with a twist channel. In this work the twist extrusion process of AA6082 T6 aluminum samples were carried out to investigate the effects of process parameters like temperature and deformation passes on the microstructure homogeneity. The results indicate that the grain refinement of AA 6082 T6 aluminum alloy leads to inhomogeneous microstructure after one twist extrusion pass. On further extrusion passes the inhomogeneity in the microstructure is found to be disappeared. The homogeneity of the distribution of the deformation was confirmed by micro hardness testing. Finite element modeling has been performed in DEFORM 3D software for determining the homogeneity of the effective strain distribution which agreed well with the experimental values.


Author(s):  
A. Lontos ◽  
K.-D. Bouzakis ◽  
G. Demosthenous ◽  
A. Baldoukas

On of the most typical forming processes used for the production of long, straight semi-finished products in the form of various section geometries is extrusion. Hot extrusion is a thermo-mechanical process whish involves complicated interactions between process parameters, tooling and deforming material /1,2/. In the present paper, FEM simulation is performed in the aluminum extrusion using circular dies with different geometries in order to extract quantitative simulating results regarding various forming parameters. Most specifically the parameters that are investigated are the die design-geometry, the process parameters (i.e. ram speed, container temperature, billet temperature) and the product quality (i.e. extruded shape, surface condition). The finite element modeling is based on 3D simulation tools using the DEFORM 3D software /3–5/. The used work piece is the aluminum AA6061 in cylindrical form with a diameter of 14 mm. The used material for the extrusion die is the hot work steel AISI H13. The geometry of the die is circular with a variation in die angle. The container and the billet temperature will vary from 450 to 550 degrees, and the mandrel (ram) speed will be at the range of 2 mm/sec. On the basis of simulating results such as pressure distribution on the extrusion die, effective stresses on the billet and product quality, new and improve die geometry will be introduced. Although the simulation problem is an axisymmetric one the authors decide to proceed with 3D FEM simulation in order to examine and verify the 3D simulating results. This paper is the first part of a further research project in which more complicated die geometries will be used as simulating and experimental specimens. In addition to simulating results, experimental results will be presented in the next few months.


2007 ◽  
Vol 364-366 ◽  
pp. 634-639 ◽  
Author(s):  
Wei Shin Lin ◽  
King Sun Lee ◽  
Shih Miao Huang ◽  
Rong Yuan Jou ◽  
Jui Chang Lin

Chips scraping each other during transportation, and chips coming into contact with water or air will cause oxidization resulting in poor quality products. The chips need to be well packed and to be protected from the environment. The method of Surface Mount Component (SMC) packing using plastic carrier tape can reduce chip damage. This study focuses on the extrusion process parameters optimization of plastic carrier tape. Because each extrusion process produces 270 pieces of carrier tape, the tape size is 1.35mmX2.25mmX1.35mm and is extremely difficult to reach the tolerance standard. This study utilized a practical test to explore various factors on the quality of the carrier tape, such as the rotational speed of extruder screw motor and extrusion mold; the negative pressure of extrusion mold; and the temperature of the extrusion mold. These experiments could find out an optimal extrusion process.


2009 ◽  
Vol 83-86 ◽  
pp. 157-164 ◽  
Author(s):  
Chao Yang Sun ◽  
Qing Dong Zhang

Superalloy IN718 large tube is used in critical jet engine applications, while manufacturing such components, the control of temperature during tube hot extrusion is of paramount importance. To determine the relation between technological factors and the temperature rise, extrusion force during tube hot extrusion of superalloy IN718, a numerical model was developed to for the large tube hot extrusion through die and over mandrel. The constitutive behaviour of the material and friction at the extrusion temperatures are established as a thermoplastic process. In order to investigate the influence of technological parameters of extrusion process on the temperatures rise and extrusion force, then the extrusion variables such as friction factor, ram speed, tool and billet preheating temperature are taking into consideration. Besides tool preheating temperature, other parameters have a great influence on temperature rise of billet during the extrusion process. All of technological parameter of study in this paper have a significant influence on the extrusion force. Moreover, based on the simulation results, the case with tool preheating temperature of 300°C should avoid during the technology making.


Author(s):  
Sarojini Jajimoggala

The simulation of hot extrusion process is a challenging problem in process modeling because of very large deformations, strain rates and temperature changes during the process. The process development in industrial extrusion is to a maximum extent based on trial and error and often involves full size experiments. Numerical simulations can replace most of these experiments, which are often both time consuming and expensive. Hence in the present work, attempt has been made to simulate hot extrusion process. AA6061-flyash Metal Matrix Composite(MMC) as billet, H13 tool steel as the die, 400oC as billet temperature and extrusion ratio of 25:4 are used as simulation parameters. Simulation is performed using software DEFORM 3D by varying ram speed, Cone Half Angle (CHA) and friction coefficient with extrusion load. The effects of change of process parameters were observed and optimal process parameters were selected.


2014 ◽  
Vol 2014 ◽  
pp. 1-10 ◽  
Author(s):  
Arun Kumar Parida ◽  
Bharat Chandra Routara

Taguchi’s design of experiment is utilized to optimize the process parameters in turning operation with dry environment. Three parameters, cutting speed (v), feed (f), and depth of cut (d), with three different levels are taken for the responses like material removal rate (MRR) and surface roughness (Ra). The machining is conducted with Taguchi L9 orthogonal array, and based on the S/N analysis, the optimal process parameters for surface roughness and MRR are calculated separately. Considering the larger-the-better approach, optimal process parameters for material removal rate are cutting speed at level 3, feed at level 2, and depth of cut at level 3, that is, v3-f2-d3. Similarly for surface roughness, considering smaller-the-better approach, the optimal process parameters are cutting speed at level 1, feed at level 1, and depth of cut at level 3, that is, v1-f1-d3. Results of the main effects plot indicate that depth of cut is the most influencing parameter for MRR but cutting speed is the most influencing parameter for surface roughness and feed is found to be the least influencing parameter for both the responses. The confirmation test is conducted for both MRR and surface roughness separately. Finally, an attempt has been made to optimize the multiresponses using technique for order preference by similarity to ideal solution (TOPSIS) with Taguchi approach.


2018 ◽  
Vol 172 ◽  
pp. 04010
Author(s):  
A. Muniappan ◽  
R. Senthilkumar ◽  
V. Jayakumar ◽  
S. Venkata Ravikumar ◽  
P. Sai Tarunkumar

The present study focused on the multiple regression modeling and predicting the surface roughness of the Aluminum hybrid composite during the WEDM process. The hybrid MMC was manufactured by process named as stir casting utilizing particulates of Silicon carbide and graphite each in Al6061 combination. The analyses were outlined with Taguchi L27 design matrix. Mathematical relationships between the surface roughness and WEDM cutting parameters (Pulse on time, Pulse off time, current, gap voltage, wire speed and wire tension) have been investigated. The results show that the multiple regression analysis is a successful method for developing a mathematical model to predict the surface roughness. The optimum value of process parameters for the predicted optimum value of surface roughness (1.285) is pulse on time 106 units (Level 1), pulse off time 60 units (Level 3), peak current 90 units (Level 2), gap set voltage 50 units (Level 3), wire speed3 units (Level 1) and wire tension 12 units (Level 3).The optimum results are adopted in validation study and the results based on WEDM process responses can be effectively improved.


2020 ◽  
Author(s):  
C Pulvermacher ◽  
P van de Vondel ◽  
L Gerzen ◽  
U Gembruch ◽  
W Merz
Keyword(s):  
Level 3 ◽  

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