Extrusion load prediction of gear-like profile for different die geometries using ANN and FEM with experimental verification

Abstract

This paper deals with the extrusion of gear-like profiles and uses of finite element method (FEM) and artificial neural network (ANN) to predict the extrusion load. In the study, gear-like components has been manufactured by forward extrusion for the AA1070 aluminum alloy and the process was simulated by using a DEFORM-3D software package to establish a database in order to provide the data for ANN modeling. Serious experiments were performed for only one die set and four teeth gear profile to obtain data for comparing with DEFORM-3D results. After verifying a highly appropriate FEM simulation with the experiment at the same conditions, Results were enhanced for different die lengths, extrusion ratios, and two extra teeth number as three and six using FEM simulations. Subsequently, the data from the performed FEM simulations were submitted for the best obtained ANN model. Finally, a good agreement between FEsimulated and ANN-predicted results was obtained. The proposed ANN model is found to be useful in predicting the forming load of the different die set variations based on the reliable test data.

Optimization of porthole extrusion dies with the developed algorithm based on finite volume method

“…In each iteration, F av is calculated according to Eqs. (12)(13). If F i in the current iteration calculated from Caffa3D module is less than F av , the area of the ith porthole should be increased to make more material flow through.…”

“…Zhao et al [12] optimized the porthole extrusion die by means of Kriging model, Latin hypercube samplings, and Pareto-based multi-objective genetic algorithm. Bingöl et al [13] predicted the extrusion load during the extrusion process of gear-like profile using artificial neural network. However, Fig.…”

Simulation of Helical Gear Forming of Az31 Magnesium Material

“…The injection upsetting method was one of the bulk forming methods and is specialized to form intricate shapes. And, for metal forming operations forming load is the most important parameter and so, it is important to estimate the forming load for the metal forming processes for optimal die design and selecting press capacity [3,7,9,14]. Mathematical methods are getting used more commonly in recent years to simulate the forming load and other process parameters which affect the quality of the product and it is possible to obtain optimum die design.…”

The Influence of Extrusion Ratio on Contact Stresses and Die Elastic Deformations in the Case of Cold Backward Extrusion

“…Simulation based on the finite element method (FEM) has made it possible to calculate the stress distribution at different cross sections of the die with the features of their shape and thermo-mechanical conditions taken into account [11] and [12], as well as to predict die damages and estimate tool life [13], to analyze die elastic deformation and the effects on part dimensional accuracy [14], and to optimize die geometry and pre-stressing procedures [15]. In some cases, FEM analysis is combined with certain methods of physical modeling [16] and artificial intelligence [17]. The goal is to gain more reliable data about loading, pressures and boundary conditions, which are then used as an input data for the simulation.…”