FEM Validation of Front End and Back End Defects Evolution in AA6063 and AA6082 Aluminum Alloys Profiles

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

doi:10.1016/j.promfg.2020.04.178

Cited by 15 publications

(6 citation statements)

References 8 publications

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“…• Sticking friction in the SolidWall regions is appropriate which complies with several other research papers [10][11][12][13][14]. • Fully stick friction (ViscoPlastic, coefficient = 1.0) in the Bearing region is appropriate for slow extrusion (ram speed of 1 mm/s in our case).…”

Section: Discussionsupporting

confidence: 67%

Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

Hoque

Hovden

Culic

et al. 2022

KEM

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In this work, different friction models available in HyperXtrude had been investigated in the context of hot forward extrusion simulation of aluminum alloys. Extrusion trials were carried out for EN AW 6060 and EN AW 6082 at different temperatures and ram speeds. The extrusion forces as well as material temperatures near the exit of the die were recorded and used for the validation of the simulations. FE-simulations of each extrusion trial were carried out in HyperXtrude. Initially, friction models were calibrated for only two extrusion trials. Then, these calibrated friction models were used to simulate the extrusion trials with different process parameters. Reasonably good agreements were observed between experiments and simulations in terms of extrusion forces. However, the simulations overpredicted the material temperature by almost up to 40 °C for extrusion trials with high ram speed.

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Section: Discussionsupporting

confidence: 67%

Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

Hoque

Hovden

Culic

et al. 2022

KEM

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“…The experimental analysis of the examined profile is reported in detail in Negozio et al [13], where an in-depth investigation on the evolution of the skin contamination defect was carried out. In Fig.…”

Section: Methodsmentioning

confidence: 99%

FEM Analysis of the Skin Contamination Behavior in the Extrusion of a AA6082 Profile

Negozio

Pelaccia

Donati

et al. 2022

KEM

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In the extrusion of aluminum alloys, the skin contamination lead to the scraping of the profile extent in which this defect occurs. In order to optimize the scraping process, extrusion companies and die makers can either perform time-consuming and expensive analyses to experimentally determine the evolution of the defect or rely on predictive methods. Recently, numerical methods, as the Finite Elements, are increasingly used to predict the evolution of the skin contamination, but their accuracy is still uncertain. In this work, an AA6082 aluminum profile of industrial complexity is analysed and the data collected used to validate an innovative method for the prediction of the skin contamination evolution developed using the commercial FEM code Qform®. In addition, the results are used to assess the prediction accuracy of an industrial empirical formula often used by operators.

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“…Even though the impact of the discard length significantly affects the overall process efficiency, few papers have been published on this subject. To the best of authors knowledge, only two studies were performed to investigate the skin defect on profiles of industrial complexity [4,5] where both front-end and back-end defects are analysed using numerical simulation with the Arbitrary Lagrangian Eulerian (ALE) approach. In [6], a Lagrangian approach was used for the simulation of the extrusion process and the skin propagation was checked by tracing the array of points located at the distance of the thickness of contaminated layer.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the skin contamination predictability by means of QForm UK extrusion code

KNIAZKIN¹

2023

Materials Research Proceedings

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Abstract. The paper presents an innovative approach implemented in QForm UK Extrusion FEM software to analyse one of the core defects encountered in profile extrusion known as billet skin defect. The validation of the algorithm has been performed based on a number of experimental case studies taken from the literature [1,2]. Additionally, the sensitivity of the accuracy of the results to the variation in initial parameters has been analysed for both types of profile shapes: solid and hollow. Based on this, practical recommendations have been formalised for the successful industrial use of the presented algorithm.

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FEM Validation of Front End and Back End Defects Evolution in AA6063 and AA6082 Aluminum Alloys Profiles

Cited by 15 publications

References 8 publications

Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

FEM Analysis of the Skin Contamination Behavior in the Extrusion of a AA6082 Profile

Investigation of the skin contamination predictability by means of QForm UK extrusion code

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