Composite Extrusion – Determination of the Influencing Factors on the Positioning of the Reinforcing Elements

Abstract

In order to manufacture a workpiece fulfilling specified requirements with the lowest possible weight, it is crucial to be able to work with a variety of materials and to combine them accordingly. The production of profiles based on hybrid materials demonstrates such an approach. The continuous and selective reinforcement of aluminum profiles with metallic elements like steel wire and steel wire ropes by composite extrusion is being investigated within the scope of research of the Transregional Collaborative Research Center (SFB/TR10). A stable production process for composite profiles with embedded continuous reinforcing elements was developed during the research work. In this paper, the process principle is shown and an overview of the special tools is given. Furthermore, the temperature and the strand speed as influencing factors on the final state of the composite are analyzed, based on real size experiments using a 2.5MN and a 10 MN extrusion press.

Combination of curved profile extrusion and composite extrusion for increased lightweight properties

“…The element bonds to the billet material under high temperature and pressure inside the die. During the process, no external force is needed to feed-in the reinforcing wires, because the billet flow applies a tensile force to the wire in the direction of the extrusion [6,7].…”

Accurate Welding Line Prediction in Extrusion Processes

“…For this reason, the use of numerical simulations becomes more interesting [8]. Especially the process conditions in the inaccessible die, such as distribution of the material flow, temperature, and pressure, can be visualized [9].…”

Knowledge-Based Modeling of Manufacturing Aspects in Structural Optimization Problems

“…Newly developed manufacturing processes such as aluminum-steel composite extrusion [8] are less well known. Several techniques are used to consider manufacturing processes in structural optimization problems.…”

“…For common manufacturing processes, broad information is available from test data such as shape distortion [6], producibility [7] and economic aspects. Newly developed manufacturing processes such as aluminum-steel composite extrusion [8] are less well known. Several techniques are used to consider manufacturing processes in structural optimization problems.…”