Coupled analysis of material flow and die deflection in direct aluminum extrusion

Assaad, W.; Geijselaers, H.J.M.

doi:10.1063/1.3552494

Cited by 7 publications

(7 citation statements)

References 3 publications

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“…The complete die set, which includes the die ring and the bolster, is being held in the press by the die slide, it also withstands a high degree of stress based on AISI H13 material used, and its high properties to withstand stress and fatigue. [14,15], as illustrated in Fig 1. Among the factors mentioned, temperature and extrusion speed are of paramount importance.…”

Section: Failure Mode and Analysis Of Extrusion Diementioning

confidence: 97%

Reliability approach for lifetime prediction of the aluminum extrusion dies

Hadji,

Benamira,

Khelif

2024

Res. Eng. Struct. Mat.

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This paper introduces a probabilistic approach for predicting the lifetime of extrusion dies using a structural reliability method known as stress-strength interference. In our investigation, we have integrated the assessment of the die's cycle life by following behavioral and rheological law. The approach relies on estimating the reliability index through a combination of a behavioral model and a reliability analysis of the hot extrusion process. Subsequently, the reliability analysis is conducted using a mechanical model to depict the most likely failure conditions. In this regard, the rheological law of Hansel & Spittel emerges as the most suitable choice, as it incorporates the mechanical properties of the materials employed in the fabrication of hot tools. The proposed mechano-reliability approach enables us to estimate reliability and its sensitivity by adjusting the parameters controlling the input process in die formation. Numerous scenarios involving extrusion dies were considered. The results demonstrate that temperature's impact on the die during the extrusion process is manifested through fatigue and damage parameters, as well as the first equivalent strain, which affect the evolution of the reliability index β and subsequently enhance the number of billets extruded.

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Section: Failure Mode and Analysis Of Extrusion Diementioning

confidence: 97%

Reliability approach for lifetime prediction of the aluminum extrusion dies

Hadji,

Benamira,

Khelif

2024

Res. Eng. Struct. Mat.

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“…The more accurate fully coupled FE analysis, which took into account the interaction of melt flow and die body deflection, were then employed by Wang and Smith [7] to predict the flow uniformity in the coat hanger die. Assaad and Geijselaers [8] also applied the fully coupled FE analysis to calculate a flat die deformation in the production of a U-shaped aluminium profile, together with the experimental validation in terms of the extrusion force and angular deflection of the tongue. Kouzilos et al [9,10] examined the mechanical stresses exerted on the spider leg of the spider type extrusion die by a fully coupled fluid-structure interaction analysis, which was realized with a commercial finite element software, COMSOL Multiphysics.…”

Section: Introductionmentioning

confidence: 99%

Coupled thermal-structural modelling and experimental validation of spiral mandrel die

Nie

Cameron

Sienz

et al. 2020

Int J Adv Manuf Technol

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The conventional theoretical method to calculate deformations and stress states is only limited to a few cases of simple extrusion dies due to a number of assumptions and simplifications. A coupled thermal-structural modelling framework incorporating finite element method is thus developed and implemented to determine the mechanical performances of the complicated spiral mandrel die, which has a complex geometrical feature of spiral grooves and is exposed to severe conditions of thermal load and high pressure. The steady-state thermal analysis is carried out by mapping the temperature load on the flow channel from previously simulated flow characteristics of polymer melt. The structural analysis takes inputs from both thermal analysis and previously simulated pressure on polymer melt. Both the temperature and pressure loads on flow channel are transferred via the Smart Bucket Surface mapping algorithm. The mechanical properties of the spiral mandrel die are evaluated by analysing the deformation and stress distribution. The experimental validation is conducted to demonstrate the effectiveness of the numerical model. The effects of both structure parameters of the spiral mandrel and processing parameters upon the maximum stress in the die body and the maximum pressure induced deformation at the die orifice are investigated.

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“…Thus, the dependence of engineers on computer-aided engineering (CAE) technologies has gradually become stronger. Currently, however, there may be ambiguity or a lack of awareness of the theoretical background of CAE technologies and their corresponding effects, and engineers tend to pay too much attention to the solution accuracy, which depends mainly on the theoretical models of the material 1–7 and die, 8–11 as well as re-meshing techniques. 12–15 Therefore, revealing the effects of these theoretical models on predictions, from the standpoint of application engineers or researchers, is of great significance.…”

Section: Introductionmentioning

confidence: 99%

“…5 tried to solve the forging process problem via a holistic method, in which deformation of material, dies, tools and machines were considered. Assaad and Geijselaers 6 presented an approach coupling material and die deformation for extrusion processes. In more recent work, Cancelos et al.…”

Section: Introductionmentioning

confidence: 99%

The effects of theoretical models of materials and die on finite element predictions in a forging process of aluminum scroll

Song¹,

Ys²,

Joun

2020

Proceedings of the Institution of Mechanical Engineers, Part E:

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In this paper, the effects of theoretical models of materials and dies on finite element (FE) predictions of a hot forging process are presented, to provide process design engineers and researchers with some useful insight into the theoretical approaches on which they rely. The material was assumed to be rigid-viscoplastic or rigid-thermoviscoplastic and the dies were assumed to be rigid or elastic. The problem of die fracture occurring during the hot forging of aluminum fixed scroll was studied. This process is particularly sensitive to theoretical models, mostly because the die-stress component causing the die fracture has a relatively weak relationship with the forming load. A fully thermo-mechanically coupled FE analysis considered die elastic deformation and was first conducted to reveal die fracture with emphasis on the maximum die stress and forming load. The predictions for four simulated cases using different theoretical assumptions of the material and die were then compared. These were also compared with experiments, undertaken to observe the relationship between maximum die stress component and forming load, to reveal the effects of material and die models in FE predictions. The differences in forming load, die stress and their variation with time among the four cases were clarified quantitatively for different die and material models, to provide some insight into metal forming for engineers and researchers.

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Coupled analysis of material flow and die deflection in direct aluminum extrusion

Cited by 7 publications

References 3 publications

Reliability approach for lifetime prediction of the aluminum extrusion dies

Reliability approach for lifetime prediction of the aluminum extrusion dies

Coupled thermal-structural modelling and experimental validation of spiral mandrel die

The effects of theoretical models of materials and die on finite element predictions in a forging process of aluminum scroll

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