An analysis of the contact stress distribution at the surface of the tooling during the CONFORM process

Abstract

The CONFORM continuous extrusion process provides outstanding features and the process has been widely used in non-ferrous metal production since it was invented. Although research and development has been quite extensive, theoretical analysis of the process has been based purely on the finite-element method, which is unable to give suitable analytical equations for calculating the stress distribution. Theoretical expressions for the contact stress distribution between the deforming material and the tools are derived in this article for the specific purpose of evaluating the load and power requirements of the machine. A simplified five sub-zone model is first established according to the different deformation characteristics in the different regions of the machine. Subsequently theoretical solutions are obtained based on simplified plasticity analysis and finally expressions are derived that can be used for calculating the load acting on the extrusion wheel and shoe. In addition, experimental verification of the theoretical results is reported.Also, much research has been carried out to investigate the process as outlined below.Cho and Jeong [5, 6] simulated the effects of the wheel diameter on the surface separation and curling phenomena as well as other significant process characteristics using the two-dimensional (2D) and three-dimensional (3D) finite-element method (FEM) for solid section aluminium products. Lu et al. [7] carried out 2D FEM simulations to determine the stress, strain, strain rate, and temperature fields for processing AA6061 aluminium alloy. Lee et al.[8] describe a 3D FEM simulation of a porthole die CONFORM extrusion process for producing aluminium multi-port-tubes used for automobile cooling systems. Reinikainen et al. [9] carried out 2D FEM simulations for CON-FORM extrusion of copper, which was assumed to take place under plane strain and isothermal conditions. Kim et al. [10] predicted the extrusion load and torque for CONFORM processing using the upper bound method.In industrial applications, there is great deal of concern regarding how to select the appropriate type and specification of a CONFORM machine in order to JPME210

Extrusion of 01417 Alloy Ingots Obtained in the Electromagnetic Crystallizer at the Conform Unit

“…При проектировании элементов крепления рабочих частей Результаты последних исследований процесса Conform при прессовании алюминиевых и медных сплавов приведены в работах [15][16][17][18]. Следует отметить, что все большее внимание уделяется компьютерному моделированию деформирования цветных металлов этим перспективным способом [19][20][21][22].…”