Numerical simulation and metal flow analysis of hot extrusion process for a complex hollow aluminum profile

Zhang, Cunsheng; Zhao, Guoqun; Chen, Hao; Guan, Yanjin; Kou, Fujun

doi:10.1007/s00170-011-3609-7

Cited by 43 publications

(13 citation statements)

References 18 publications

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“…The goal of the extrusion die design is to ensure the velocity in the extruded product is evenly distributed, and it is a decisive factor in the quality of the extruded product [31,32]. The velocity relative difference (VRD) shown in Equation (4) is used to assess the overall level of the velocity distribution of the extruded product [10,31,33].…”

Section: Extrusion Velocity Of the Productmentioning

confidence: 99%

Effects of Solid Die Types in Complex and Large-Scale Aluminum Profile Extrusion

Truong

Hsu²,

Tong

2019

Applied Sciences

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Increasing customer requirements for quality and productivity in extruding aluminum products has led to the development of different types of extrusion dies. In this study, three different types of dies, including traditional flat die, pocket die and spread die were designed to extrude complex and large-scale solid profiles. The design parameters for these dies were used from actual extrusion experience. The results obtained from steady-state simulation such as velocity, temperature, extrusion force, and die deformation were used to assess the advantages and disadvantages of the dies. Transient simulations were performed to analyze the evolution of transverse weld in the pocket and spread dies. The effects of ram speeds on the related extrusion parameters were also investigated. The research results provide useful guides for designers and engineers in selecting these types of extrusion dies. parameters of extrusion process can be obtained such as extrusion velocity, product temperature, die deformation, die stress, welding seam etc. [10][11][12]. studied. To balance the metal flow in the extrusion product, the dies were designed with a 3D model using practical experience parameters. After that, numerical simulations of extrusion were conducted by HyperXtrude 2017 software (Altair Engineering, Inc., Michigan, USA) with the Arbitrary Lagrangian-Eulerian (ALE) algorithm. The steady-state extrusion parameters, such as extrusion force, velocity, temperature, and die deformation, were investigated. The transient simulation is utilized to explore the evolution of transverse weld in the billet-to-billet extrusion process of the pocket, and the spread dies. Finally, the effects of ram speeds on the related extrusion parameters were examined. The advantages and drawbacks of these die types are analyzed and evaluated based on the obtained parameters from simulations.

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Section: Extrusion Velocity Of the Productmentioning

confidence: 99%

Effects of Solid Die Types in Complex and Large-Scale Aluminum Profile Extrusion

Truong

Hsu²,

Tong

2019

Applied Sciences

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“…The buckle angle in the inlet side of the upper die is used for billet overflow resistance. Some previous efforts pointed out that these structure designs may help to get a balance metal flow and reduce the forming load during the hot extrusion of aluminum alloys [9,12]. Figures 3 and 4 show the main structures of the lower die with the two-step welding chamber and the non-uniform bearing length distribution, respectively.…”

Section: The Main Structure Design Of the Multi-output Porthole Extrumentioning

confidence: 99%

“…The arbitrary Lagrangian Eulerian (ALE) algorithm has been adopted for the hot extrusion simulation of complex profiles [9,12]. This is because the ALE method is a combination of Lagrangian and the Eulerian approach, in which the mesh distortion and the difficulty of the free surface tracking can be effectively avoided.…”

Section: Basic Theories Of Numerical Algorithm and Materials Modelmentioning

confidence: 99%

“…They reported that multi-hole processes are more suitable for the mass production of small-sized components than single-hole solutions. Zhang et al investigated the effects of the uniformity of the material flow on the extrusion load via the signal-to-noise ratio using the Taguchi method [9]. The effects of several process parameters were examined, including the billet diameter, the ram speed, the temperature fields for the metal flow, and the extrusion force.…”

Section: Introductionmentioning

confidence: 99%

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Assessment of Metal Flow Balance in Multi-Output Porthole Hot Extrusion of AA6060 Thin-Walled Profile

Xue

Vincze

Péreira

et al. 2018

Metals

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For the porthole hot extrusion of a thin-walled tube based on metal flow, the role of the die's structure should be focused on to achieve precision formation, especially for multi-output extrusion and/or complex cross-sectional profiles. In order to obtain a better metal flow balance, a multi-output porthole extrusion die was developed, including some novel features such as a circular pattern of the portholes with a dart-shaped inlet bridge, a buckle angle in the inlet side of the upper die, a two-step welding chamber, and a non-uniform bearing length distribution. Through the use of thermo-mechanical modeling combined with the Taguchi method, the underlying effects of key die features were investigated, such as the billet buckle angle, the porthole bevel angle, the depth of the welding chamber, and the type of bridge on the metal flow balance. The experimental validation showed that the developed numerical model for the multi-output porthole extrusion process had high prediction accuracy, and was acceptable for use in an industrial extrusion with a complex section.

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“…During thermo-mechanical treatments, the covered oxide layer breaks due to highly induced shear stress, leading to a strongly bonded microstructure and improved mechanical properties which eliminate the main drawback of AMCs (Schatt et al 1997). The use of traditional shear-faced die in extrusion causes product defects owing to the existence of higher velocity relative difference at die exit (Zhang et al 2012a;2012b). The use of mathematically contoured die (preferably zero, die entry and exit angle) for the MMC extrusion is highly recommendable.…”

Section: Introductionmentioning

confidence: 99%

Synthesis and characterisation of hot extruded aluminium-based MMC developed by powder metallurgy route

Mohapatra

Maity

2017

Int J Mech Mater Eng

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Background: Improvement of the mechanical and tribological properties due to extrusion can be attributed to the improved density and excellent bond strength due to high compressive stress. Methods: To avoid the product defects mathematically contoured cosine profiled die was used for the thermomechanical treatment. Improvement of mechanical characterization like density, hardness, compression test and three-point-bend test was inquired. Two body dry sliding wear behaviour of the prepared AMCs before and after extrusion were investigated by using a pin-on-disc wear testing method by varying the variable parameters like load (N), track diameter (mm) and RPM of the counter disc. Results: The effect of hot extrusion on mechanical and tribological characteristics of aluminium matrix composites (AMCs) developed by powder metallurgy route followed by double axial cold compaction and controlled atmospheric sintering was studied. Conclusion: Shearing of the fine distributed graphite particles at the tribosurface acts as a solid lubricant and decreases wear rate. At higher loading and sliding velocity condition a mixed type of wear mechanism was observed.

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Numerical simulation and metal flow analysis of hot extrusion process for a complex hollow aluminum profile

Cited by 43 publications

References 18 publications

Effects of Solid Die Types in Complex and Large-Scale Aluminum Profile Extrusion

Effects of Solid Die Types in Complex and Large-Scale Aluminum Profile Extrusion

Assessment of Metal Flow Balance in Multi-Output Porthole Hot Extrusion of AA6060 Thin-Walled Profile

Synthesis and characterisation of hot extruded aluminium-based MMC developed by powder metallurgy route

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