Modeling of aluminum alloy profile extrusion process using finite volume method

Lou, Shumei; Zhao, Guoqun; Wang, Rui; Wú, Xiànghóng

doi:10.1016/j.jmatprotec.2007.12.084

Cited by 37 publications

(30 citation statements)

References 9 publications

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“…Knowing that, FEM and FDM do not satisfy conservations laws in discrete level because they do not work with control volumes but with mesh points [4]. Then, from the 1990s, a lot of works appeared in literature to numerically simulate metal forming process by FVM and flow formulation [6,7,9,11,12,14,18].…”

Section: Finite Volume Analysis With the Maccormack Methods Applied Tomentioning

confidence: 99%

“…The mathematical modelling in metal flow of forward extrusion can be treated by FVM using flow formulation [1,6,11,14,15,18]. According [15] metal flow is considered similar to fluid viscous flow.…”

Section: Governing Equationsmentioning

confidence: 99%

“…In the metal forming area, it is not different. There are many scientific papers published to evaluate metal forming phenomena by numerical simulation [1,6,7,9,11,12,14,18]. This is because computer has steadily increased the processing power since the 1950's [4,8,15,17].…”

Section: Introductionmentioning

confidence: 99%

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Finite Volume Analysis with the MacCormack Method Applied to Metal Flow in Forward Extrusion

Martins¹,

Bressan²,

Button³

2017

ujme

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Computational numerical simulation has been largely applied in the design and analysis of metal forming processes. Extrusion is one of the main forming processes largely applied in the manufacturing of metallic products or parts. Historically, the Finite Element Method (FEM) has been applied for decades in metal extrusion analysis. However, recently in the academy, there is a trend to use the Finite Volume Method (FVM), because literature suggests that metal flow by extrusion can be analyzed by the flow formulation. Thus, metal flow can be modelled as an incompressible viscous fluid. The MacCormack Method is commonly used to simulate compressible fluid flow by the FVM. However, metal extrusion does not present state equations to calculate the pressure, and therefore, a velocity-pressure coupling method is necessary to obtain consistent velocity and pressure fields. This work proposes a new numerical scheme to obtain information about metal flow in the extrusion process along the steady state. The governing equations were discretized by FVM, using the Explicit MacCormack Method to structured and collocated mesh. The SIMPLE Method was applied to attain pressure-velocity coupling. This new numerical scheme was applied to analyze forward extrusion of lead. The metal extrusion velocity fields were calculated with a fast convergence and presented a good agreement with analytical and experimental results obtained from literature.

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Section: Finite Volume Analysis With the Maccormack Methods Applied Tomentioning

confidence: 99%

Section: Governing Equationsmentioning

confidence: 99%

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Finite Volume Analysis with the MacCormack Method Applied to Metal Flow in Forward Extrusion

Martins¹,

Bressan²,

Button³

2017

ujme

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“…Lou et al reported that this method could cover from fundamental analysis on the metal flow of simple geometry to a complex profile 1) and Jo verified theoretical formulas for extrusion forces with an extrusion experiment. 2) Fang et al also showed that preliminary analysis on the extrusion process could significantly minimize trial-and-errors confronting practices in their previous researches.…”

Section: Introductionmentioning

confidence: 90%

Analysis of the Aluminum Extrusion Process Equipped with the Continuous Heat Treatment System

Lee¹,

Cho²,

Lee³

et al. 2011

Korean. J. Mater. Res.

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In this study, the heat flow of the plant scale aluminum extrusion process was investigated to establish optimum continuous heat treatment conditions. During the extrusion of 6061 aluminum alloy, processing parameters such as the extrusion pressure, speed and temperature histories of billets were logged as a function of time. The surface temperature of the billets increased at constant ram speed, while it decreased with decreases of the ram speed. In order to maintain the billet temperature within a solutionizing temperature range prior to the succeeding water quenching step, the ram speed or the temperature of the blower should be controlled. The temperature histories of the billets during the extrusion and hot air blowing processes were successfully simulated by using the velocity boundary model in ANSYS CFX. The methodology to design an optimum process by using a commercial simulation program is described in this study on the basis of the metallurgical validation results of the microstructural observation of the extrudates. The developed model allowed the advantages of taking into account the motion of the extrudate coupled with the temperature change based on empirical data. Calculations were made for the extrudate passing through the isothermal chamber maintained at appropriate temperature. It was confirmed that the continuous heat treatment system is beneficial to the productivity enhancement of the commercial aluminum extrusion industry.

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“…The strain inhomogeneity decreases with the increasing of the fillet radius of the die and the lowest one was obtained for the fillet radius of r f = 3.0 mm. The strain distribution and other important variables that influence material structure, such as hydrostatic stress, are strongly dependent on the geometry of the extrusion dies [26][27][28][29] . This correlation between die fillet radius and the flow uniformity is also confirmed by the results of calculation of other process parameters like velocity, shown in figure 6, and hydrostatic pressure, shown in figure 9.…”

Section: Figura 3 Evolución De La Microestructura Durante El Procesmentioning

confidence: 99%

Effect of die shape on the metal flow pattern during direct extrusion process

Solomon¹,

Solomon²

2010

REVMETAL

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The geometric shape of the tools is the main factor by which an optimum technological process can be developed. In the case of extrusion process the strain distribution and other important variables that influence material structure, such as hydrostatic stress, are strongly dependent on the geometry of the die. Careful design of the extrusion die profile can therefore control the product structure and can be used to minimise the amount of inhomogeneity imparted into the product. A possibility to minimise the amount of product inhomogeneity is the using of a flat die with a fillet radius in front to the bearing surface with leads to a minimum dead zone and consequently to a minimum friction at billet-container interface. In the case of aluminium alloy type 2024, for an extrusion ratio of R=8.5, good results were obtained with a fillet radius of 3.0 mm. The experimental data have been used for the finite element numerical simulation of the extrusion process. The data obtained by numerical simulation with FORGE2 programme confirm the theoretical and experimental outcomes. The aim of this paper is to study the influence of such flat die on the material flow during direct extrusion process and consequently on extruded product microstructure and mechanical properties. KeywordsMetal flow pattern; Flat die; Friction; Finite element; Equivalent strain.Efecto de la forma del molde sobre el flujo de metal durante el proceso de extrusión directa ResumenLa forma geométrica de las herramientas es el principal factor a través del cual un proceso óptimo de deformación plás-tica puede ser mejor desarrollado. En el caso del proceso de extrusión, la distribución de la deformación y otras variables importantes, como la presión hidrostática, que pueden influir en la estructura del material, son fuertemente dependientes de la geometría del molde. Mediante un diseño apropiado del perfil del molde de extrusión se pueden controlar la estructura y las propiedades mecánicas del producto y, por lo tanto, se puede utilizar para minimizar la cantidad de la no homogeneidad del producto. Una posibilidad para reducir al mínimo la cantidad de no homogeneidad del producto es utilizar un molde recto provisto de un radio de conexión en la zona de deformación, que puede causar una reducción al mínimo de la zona muerta y, así, reducir al mínimo la fricción en la interfase entre el semiacabado y el contenedor del molde. En el caso de la aleación de aluminio de tipo 2024, para una relación de extrusión, R = 8,5, los mejores resultados se obtuvieron con un radio de conexión de 3,0 mm. Los datos experimentales se utilizaron para la simulación numérica del proceso de extrusión. Los resultados experimentales obtenidos mediante el uso de simulación numérica con el programa FORGE2 confirman los resultados teóricos y experimentales. El propósito de este trabajo es estudiar la influencia de este tipo de matrices con un radio de conexión en la zona de deformación en el flujo de material durante el proceso de extrusión y por tanto en la microestructura y...

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Modeling of aluminum alloy profile extrusion process using finite volume method

Cited by 37 publications

References 9 publications

Finite Volume Analysis with the MacCormack Method Applied to Metal Flow in Forward Extrusion

Finite Volume Analysis with the MacCormack Method Applied to Metal Flow in Forward Extrusion

Analysis of the Aluminum Extrusion Process Equipped with the Continuous Heat Treatment System

Effect of die shape on the metal flow pattern during direct extrusion process

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