Extrusion of Light and Ultralight Alloys with Liquid Nitrogen Conformal Cooled Dies: Process Analysis and Simulation

Pelaccia, Riccardo; Negozio, Marco; Donati, Lorenzo; Reggiani, Barbara; Tomesani, Luca

doi:10.1007/s11665-021-06320-z

Cited by 8 publications

(6 citation statements)

References 29 publications

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“…4b). The numerical approach based on the 1D modelling of the nitrogen cooling was tested and validated in different previous works of the authors [8][9][10][11], proving the good accuracy of the achieved results at very reduced computational time if compared to the approach based on a full 3D model of the nitrogen flow. In this work, the accuracy of the numerical model was demonstrated by analyzing, in terms of temperature prediction, the experimental-numerical differences in both uncooled and cooled conditions.…”

Section: Numerical Model Of Extrusion Process With Nitrogen Coolingmentioning

confidence: 73%

“…In addition, the level of complexity force not only through numerical approaches, but also demands for automated, robust and comprehensive methodologies. If many works have been reported on aluminum extrusion FE (Finite Element) modelling [6,7], stating the robustness and reliability of the approach, only recently Reggiani and Donati [8], and Pelaccia et al [9,10] proposed a comprehensive numerical model for the prediction of the thermal gradient during the extrusion process with nitrogen cooling. In addition, very promising results have already been achieved, by the same authors, by integrating the comprehensive FE model in an optimization platform able to change the channel sections iteratively and automatically along the path [11].…”

Section: Introductionmentioning

confidence: 99%

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Investigation on the topological optimization of cooling channels for extrusion dies

Pelaccia

2023

Materials Research Proceedings

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Abstract. During the extrusion process, high temperatures are generated, due to friction and deformation works, potentially leading to profile and die defects. Among the suggested solutions aimed at controlling the thermal field of the process, the most accredited one involves the manufacturing of cooling channels at the mating face between the die and a third plate. Despite the proven efficiency of well-designed channels, the main drawback lies in the managing of the many variables involved that strongly affect the cooling efficiency and balancing. In this frame, aim of the work is to investigate the applicability of the topological optimization tool, proposed by COMSOL Multiphysics software, for the design of cooling channels in extrusion dies. To validate the tool, an industrial case study has been selected and results compared between not optimized and optimized cooling solutions.

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Section: Numerical Model Of Extrusion Process With Nitrogen Coolingmentioning

confidence: 73%

Section: Introductionmentioning

confidence: 99%

Investigation on the topological optimization of cooling channels for extrusion dies

Pelaccia

2023

Materials Research Proceedings

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“…The authors of the paper have still proposed a numerical model for the thermal field prediction during the extrusion process, modelled as 3D, with nitrogen flowing in a simplified 1D channel [9][10][11]. These works provided the basis for the present paper, in which the FE model of the cooled extrusion process was integrated within the optimization platform, modeFRONTIER®, with the aim to automatically detect the optimal channel design.…”

Section: Introductionmentioning

confidence: 99%

Assessment of the Optimization Strategy for Nitrogen Cooling Channel Design in Extrusion Dies

Pelaccia

Negozio

Reggiani

et al. 2022

KEM

Self Cite

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Aluminum extrusion is an efficient industrial process. However, one of the main problems is related to the temperatures developed during the process that can detrimentally affect the achievable productivity, profile quality and/or die life. Cooling of the die with liquid nitrogen represents an efficient solution to overcome this limit but a further issue arises lying in the number of process and design variables that need to be managed in order to set-up of an efficient system. In this context, a 3D FE model of the extrusion process, coupled with a 1D model of the cooling channel, previously proposed by the authors, has been integrated in an optimization platform in order to iteratively and automatically adjusts the channel geometry and the process variables gaining to a final optimal solution in terms of thermal balance, cooling efficiency and nitrogen consumption. The original channel design used during the extrusion of industrial hollow AA6060 profile guaranteed an efficient but unbalanced cooling with a maximum temperature deviation of 60 °C registered by the thermocouple positioned around the bearings. The optimized designs showed temperature deviations below the 16 °C as well as the reduction of 50% in terms of nitrogen consuming.

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“…The capability of nitrogen cooling within a conformal channel was experimentally and numerically assessed, for the extrusion of AA6063 aluminium and ZM21 magnesium alloys. 28 A platform for testing the liquid nitrogen cooling for multi-die design was proposed. 29 To provide extruders and die manufacturers with a numerical tool particularly for the thermal distributions of dies, a FEM model for the extrusion process with the liquid nitrogen cooling system was developed.…”

Section: Introductionmentioning

confidence: 99%

“…presented a finite element method (FEM) to cool down channels, which is mainly for die plastic injection molding and casting applications. The capability of nitrogen cooling within a conformal channel was experimentally and numerically assessed, for the extrusion of AA6063 aluminium and ZM21 magnesium alloys 28 . A platform for testing the liquid nitrogen cooling for multi‐die design was proposed 29 .…”

Section: Introductionmentioning

confidence: 99%

A novel combo‐transmission system of cold energy and electricity for aluminium profile production: Using liquid nitrogen and superconductor technologies

Chen

Jiang

et al. 2022

Energy Science & Engineering

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Aluminium production needs the most energy‐intensive technologies among all the metal processing sectors. During the process of aluminium profile extrusion, the whole production line needs bulk electricity, and the mold inside the extrusion equipment needs robust cold energy for rapid cooling of the metal surface. This paper presents a new combo‐transmission that can simultaneously deliver cold energy together with electricity to the aluminium profile extrusion line. Thanks to the superiority of virtually zero loss and compact size, the powerful superconducting cable is used to replace the conventional copper cable. The entire superconducting cable assembly is fully installed into a cryogenic pipeline and cooled by liquid nitrogen at 77 K. In addition to keeping a favourable cryogenic environment for the superconducting cable, liquid nitrogen can also provide a large amount of cold energy for cooling the metal surface. For a typical 100 MN aluminium extrusion production line, the design and optimization of 10 kA class superconducting cable with the pipeline cooling system for aluminium production are presented in detail. The simulation results and comparisons show that the total energy loss of superconducting transmission is about 46% of conventional copper cable, and the energy saved in a year can be up to about 240.6 MWh. Moreover, the net profit increases almost linearly along with the increases of the extrusion speed when the liquid nitrogen cooling is applied to the 100 MN production line. For the case of 23% increase in extrusion speed, the net profit can be up to 1.48 M$ in a year. Overall, the novel design, technical evaluation, and economic analysis of the combo‐transmission system (cold energy + electricity) can provide a promising solution for future high‐dense aluminium production sectors.

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Extrusion of Light and Ultralight Alloys with Liquid Nitrogen Conformal Cooled Dies: Process Analysis and Simulation

Cited by 8 publications

References 29 publications

Investigation on the topological optimization of cooling channels for extrusion dies

Investigation on the topological optimization of cooling channels for extrusion dies

Assessment of the Optimization Strategy for Nitrogen Cooling Channel Design in Extrusion Dies

A novel combo‐transmission system of cold energy and electricity for aluminium profile production: Using liquid nitrogen and superconductor technologies

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