A Special Extrusion-shear Manufacturing Method for Magnesium Alloy Rods Based on Finite Element Numerical Simulation and Experimental Verification

To research the influences of process parameters on a special extrusion-shearmanufacture method for magnesium alloy rods, deform-3d software with finite elementsimulations has been used to analyze the material flows of deformed magnesium alloysAZ31B during the extrusion-shear (ES) process, as well as the grain sizes anddistribution of extrusion loads, stresses and strains, and blank temperatures. Temperaturefields, stress fields, strain fields and temperature fields varying with different blankpreheating temperatures, extrusion speed and extrusion ratios were simulated. Influences ofdifferent extrusion conditions and different die structures on microstructures of rods prepared by ES process has been researched. Extrusion forces decrease with the increasing extrusion temperatures, decreasing extrusion ratios, increasing die channel angles and decreasing friction coefficients. The flow velocities of metal in the ES die increase with development of ES process. Increasing the channel angles and reducing the friction factors would increase the outflow velocities of metal, but it has little effect on the uniformity of metal flow. The increase in friction and extrusion speed would increase the temperatures of the ES die. The ES process can prepare finer and more uniform microstructures than those prepared by direct extrusion under the same conditions.

NUMERICAL SIMULATION OF ECCENTRICITY CREATION IN THE PRODUCTION OF HOT ROLLED TUBES

The paper deals with the issue of eccentricity in the technological node of the piercing press, under selected conditions, which result from the possibilities of production in the conditions of ŽP a.s. These conditions were verified and adapted to the rolling process. This process consisting of individual technological nodes on the rolling mill, in which eccentricity is created on the piercing press and the following steps eliminate it in other technological nodes. For quality analysis of manufacturing tubes using numerical simulation, it is necessary to know the actual state of eccentricity creation on the rolling mill. A numerical simulation of piercing under different input conditions was used (software DEFORM-3D) and was performed for several different charge states before entering onto the piercing press. The eccentricity itself has a significant effect on the resulting geometric quality of the tubes.

Optimization of Drilling Parameters During Machining of Al-Mg-Si Alloys By Taguchi Method Coupled with Grey Relational Analysis and Validated By Fea Based Deform - 3D

In the present work to validate the experimental results as per Taguchi based grey relational analysis by considering L27 orthogonal array corresponding to five factors with three levels and obtained optimal combination of input parameters to minimize the output responses during drilling process which is most important finishing operation required in the structural assembly works where we found application of Al-Mg-Si alloys, Deform-3D software is implemented and found good feasibility with that of experimental results.

The effect of die radius on thickness distribution of SS304 stainless steel sheet in deep drawing of cylindrical cup

Thickness distribution of deep drawing products has been studied in recent decades since it has a significant influence on the product quality. In this paper a numerical simulation with experimental verification was conducted to examine the influence of die radius on the thickness distribution of cilindrical cup in deep drawing for SS304 stainless steel. Thickness distribution of the cup was analyzed through the stress-strain state during deep drawing by Deform 3D software. The obtained results allow choosing a reasonable die radius to achieve more uniform wall thickness of the cup, that optimizes tool design and reduces manufacturing costs.

Research the Effect of Speed Mismatch during Continuous Rolling on the Plasticity Margin

The paper analyzes the influence of tension (dam) on the stress-strain stain and plasticity margin. For the analysis, a model of continuous rolling in three adjacent stands was developed using the Deform 3D software. The adequacy of the model was confirmed by comparing the experimental data from the small-section wire mill 150 and the simulation results. Further, a computational experiment was planned to identify the effect of mismatched of rolling speeds on stress-strain stain. It is shown that for small deviations of rolling speed from the matched mode, there is no significant change in the reserve plasticity along the specific trajectory of the particles movement.

Development of Calibration Knives for Hot Cutting Shears

In this paper, the problem distortion the end of a cylindrical workpiece in the cutting process on hot shears before being fed to the piercing mill is considered. To solve this problem, a new calibration of knives has been developed, and a finite element model hot cutting shears has been developed using the DEFORM-3D computer simulation software package. Modeling the cutting process using the proposed calibration has been carried out. It was found that the knife calibers geometry plays an important role in the formation end part geometry of the blank. Based on the simulation results, it was concluded that proposed calibration reduces the ovality workpiece end by almost 2 times in comparison with current calibration. Recommendations have been developed for the production of changes in the existing technology for cutting pipe billets.

Hot Deformation Behavior and Dynamic Recrystallization of Ultra High Strength Steel

In this paper, in order to improve the microstructure uniformity of an ultra-high strength martensitic steel with a strength greater than 2500 MPa developed by multi-directional forging in the laboratory, a single-pass hot compression experiment with the strain rate of 0.01 to 1 s−1 and a temperature of 800 to 1150 °C was conducted. Based on the experimental data, the material parameters were determined, the constitutive model considering the influence of work hardening, the recrystallization softening on the dislocation density, and the recrystallized grain size model were established. After introducing the model into the finite element software DEFORM-3D, the thermal compression experiment was simulated, and the results were consistent with the experimental results. The rule for obtaining forging stock with a uniform and refinement microstructure was acquired by comparing the simulation and the experimental results, which are helpful to formulate an appropriate forging process.

Influences of Expanding Angles on Extrusion-Shearing-Expansion Processing of AZ31 Magnesium Alloy Thin-Walled Tubes

To research the influence mechanisms of expanding angles on extrusion-shearing-expansion(ESE) process of AZ31 magnesium alloy thin-walled tubes,the effects of different expanding angles on microstructures and mechanical properties of AZ31 magnesium alloy during extrusion-shear-expansion process have been investigated by optical microscope(OM),scanning electron microscope (SEM),X-ray diffractometer(XRD).Three expanding angles 130°,140°,150° have been used.The forming loads varying with expanding ratios,and equivalent strains at various expanding angles have been simulated by Deform-3D software.The research results show that the qualities and mechanical properties of the formed tube are satisfactory, and extrusion-shearing-expanding process can refine the grain of AZ31 magnesium alloy thin-walled tubes.The grain sizes decrease with the decrease of expanding angles.When the expanding angle is 140°,the comprehensive mechanical properties are best,and yield strength is 122.3MPa,the tensile strength 288.6MPa,the elongation 15.2%, the texture intense is optimized due to the DRX.The deflections of basal plane for most grains are obvious relative to the extrusion direction(ED).