Application of finite element method in the hot extrusion of aluminium alloys

Duan, Xinjian; Velay, Xavier; Sheppard, T.

doi:10.1016/j.msea.2003.10.275

Cited by 68 publications

(39 citation statements)

References 21 publications

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“…The Cockroft -Latham criterion is very high there (approx. 1.0) and can exceed the boundary values depending on the aluminum alloy [11], which can even lead to material cracking. Interestingly, the mechanism of crack formation will differ depending on the workpiece region.…”

Section: Numerical Modelingmentioning

confidence: 99%

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Tofil¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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The paper presents a selection of numerical and theoretical results of the cross wedge rolling process for producing stepped shafts made of aluminum alloy 6061. The numerical modeling was performed using the FEM-based Simufact Forming simulation software. In the simulations, we examined the kinematics of metal flow and determined the distribution patterns of effective strains, temperatures, axial stresses and the Cockroft-Latham damage criterion. Variations in the rolling forces were determined, too. The numerical results were verified experimentally using a universal rolling mill designed and constructed by the present authors. This machine can be used to perform such processes as cross wedge rolling, longitudinal rolling and round bar cropping. During the experiments, we examined process stability and finished product geometry and recorded the torques. The experimental results confirm that axisymmetric aluminum alloy shafts can be produced by cross wedge rolling with two rolls. Last but not least, the experiments served to evaluate the technological potential of the rolling mill used.Keywords: cross wedge rolling, aluminum alloys, FEM, experiment W pracy przedstawiono wybrane wyniki badań teoretyczno -doświadczalnych procesu walcowania poprzeczno -klinowego odkuwki wałka stopniowanego ze stopu aluminium w gatunku 6061. Analizę teoretyczną przeprowadzono w programie Simufact Forming, bazującym na metodzie elementów skończonych. W trakcie symulacji analizowano kinematykę płynięcia materiału, wyznaczono rozkłady intensywności odkształcenia, temperatury, naprężeń w kierunku osiowym oraz kryterium zniszczenia wg Cockrofta Lathama. Ponadto określono parametry siłowe podczas walcowania. Weryfikacji doświadczalnej wyników modelowania numerycznego procesu walcowania dokonano w uniwersalnej walcarce kuźniczej, która stanowi własna konstrukcję. Zastosowana walcarka umożliwia realizacje takich procesów jak: walcowanie poprzeczno-klinowe, walcowanie kuźnicze wzdłużne oraz dzielenie bezodpadowe. Podczas eksperymentu analizowano stabilność procesu, geometrie ukształ-towanych odkuwek oraz rejestrowano wartość momentów obrotowych. Uzyskane wyniki prowadzonych badań potwierdziły możliwość kształtowania osiowosymetrycznych odkuwek ze stopów aluminium metodą WPK dwoma walcami. W trakcie eksperymentu określono również możliwości technologiczne walcarki.

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Section: Numerical Modelingmentioning

confidence: 99%

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Tofil¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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“…In their study, the integrity of the extruded composite rod was very good at a minimum extrusion speed of 1 mm/s whereas extrusion speeds of 10 mm/s and 100 mm/s resulted in fir tree cracking. While the study carried out by Duan 22 , et al indicates that the greater the extrusion ratio, the less possibility of occurrence of surface cracks. The maximum billet temperature and the allowable amount of deformation are determined by the temperature at which incipient melting or hot shortness occurs.…”

Section: Surface Quality Of Extrudatesmentioning

confidence: 97%

Finite Element Analysis and Experimental Study on the Effect of Extrusion Ratio during Hot Extrusion Process of Aluminium Matrix Composites

et al. 2017

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The finite element (FE) analysis on the effect of extrusion process parameter namely, extrusion ratio at different billet temperatures on the plastic strain and strain rate of aluminium matrix composite during hot extrusion process has been dealt. The dynamic explicit FE code in ANSYS 15.0 workbench was used for simulation. The FE analysis was carried out on the SiC reinforced aluminium matrix composites for three extrusion ratios 4:1, 8:1 and 15:1, for the billet temperatures in the range 350 °C -450 °C in steps of 50 °C. The plastic strain and strain rate were found to increase with increase in the extrusion ratio. A minimum strain and strain rate was found to occur at the billet temperature of 450 °C. The silicon carbide particles reinforced aluminium matrix composites were then extruded at the optimised temperature of 450 °C for various extrusion ratios as mentioned above. The effect of extrusion ratio on the microstructure and surface quality of extruded rod was studied.

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“…The normalized form of the Cockcroft and Latham criterion can be expressed as in the following: (1) where is equivalent stress, σ I the maximum principal tensile stress, the equivalent strain, the equivalent strain to fracture, and CL is the critical damage value [15]. In this approach, the most important factor is to determine the critical damage value CL.…”

Section: Surface Crack Prediction Of Extruded Bar Using Fem Simulationmentioning

confidence: 99%

Effect of scandium on the hot extrudability of 7075 aluminum alloy

et al. 2010

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This study investigated the effect of the addition of scandium on the hot extrudability of 7075 alloys. Three kinds of Al-Zn-Mg-(Sc) alloys with up to 0.30 wt.% Sc were prepared, including 7075 aluminum alloy without Sc (AA7075). Differential scanning calorimetry (DSC) analyses and hot compression tests were conducted to examine the incipient melting temperature of the alloys produced. The addition of 0.30 wt.% Sc resulted in significant grain refinement and a fully equiaxed microstructure. Hot compression tests were conducted to determine the critical damage values based on Cockroft-Latham criterion. Then, the surface quality of an extruded bar of each alloy was simulated with a finite element code. The surface condition of an extruded bar was predicted and compared with the experimental results. After hot extrusion, AA7075 without the addition of Sc showed a more moderate surface quality than the alloys modified with Sc. However, AA7075 revealed coarse-grained bands just below the surface area. Extrusion limit diagrams were constructed for the three alloys.

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Application of finite element method in the hot extrusion of aluminium alloys

Cited by 68 publications

References 21 publications

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Finite Element Analysis and Experimental Study on the Effect of Extrusion Ratio during Hot Extrusion Process of Aluminium Matrix Composites

Effect of scandium on the hot extrudability of 7075 aluminum alloy

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