Simulation of extrusion process of complicated aluminium profile and die trial

Zhang, He; Wang, He-nan; Wang, Mengjun; Li, Guangyao

doi:10.1016/s1003-6326(11)61380-0

Cited by 35 publications

(13 citation statements)

References 12 publications

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“…He et al [6] propose an intelligent system that requires a large amount of information, such as operational data, maintenance data, fault data, decision data correction, etc., reflecting the status of the non-conformance, then use this information to develop the case-base.…”

Section: History Of Casesmentioning

confidence: 99%

Building a Case Base for the Non-Conformance Problem Solving in the Aluminum Extrusion Process

Pacheco

Ferreira

Mikos

2013

Advances in Sustainable and Competitive Manufacturing Systems

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This work proposes the application of Case-Based Reasoning (CBR) to build a knowledge base system for seeking and providing solutions for non-conformances that take place in the aluminum extrusion process. CBR is an important area of Artificial Intelligence (AI) that is used to solve problems based on the knowledge accumulated previously from known scenarios, providing a solution to both recurrent and new problems. The CBR cycle is characterized by having four stages known as: retrieval, reuse, revision, and retention. These stages interact with the knowledge base in order to seek one or more solutions to the problem. The steps for the development of the relational model of the knowledge base according to CBR are as follows: (a) identification and classification of the non-conformances, (b) information gathering of situations that result in non-conformances, which include: records of non-conformances, experience of operators with nonconformances, literature on non-conformances in the aluminum extrusion process, and (c) the structure definition for the diagnosis of cases of non-conformance and support in decision-making. The final step consists in storing the cases in a relational database, which will correspond to a knowledge base. New cases may be added in the knowledge base, as they occur. The structure of the cases in the knowledge base will be important for its provision for decision-making in the aluminum extrusion process. In a further work it is intended to implement a webbased distributed system to support the inclusion of new cases (that may occur in different geographic locations and company conditions) as well as a fast search for solutions to non-conformances that occur in the aluminum extrusion process.

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Section: History Of Casesmentioning

confidence: 99%

Building a Case Base for the Non-Conformance Problem Solving in the Aluminum Extrusion Process

Pacheco

Ferreira

Mikos

2013

Advances in Sustainable and Competitive Manufacturing Systems

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“…An unstructured mesh is applied to the lead surface to allow better remeshing of elements under deformation (Tu et al 2018). The ALE finite-element method is used to simulate large deformation problems, allowing a moving mesh along with the moving part (Gadala and Wang 2000;Zhao et al 2012; © ASCE 04021227-3 Zhuang et al 2008;Yildirim et al 2011). The motion of the mesh is only constrained at the boundaries and allowed to move under high strain within these fixed boundaries.…”

Section: Fe Model Descriptionmentioning

confidence: 99%

Nonlinear Finite-Element Modeling of HF2V Lead Extrusion Damping Devices: Generic Design Tool

2022

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Supplemental energy-dissipation devices are increasingly used to protect structures, limiting loads transferred to structures and absorbing significant response energy without sacrificial structural damage. The displacement of the bulged shaft plastically deforms lead in the high force to volume (HF2V) device, dissipating significant energy. HF2V devices are currently designed using limited precision models, so there is variability in force prediction. Further, although the outcome force is predicted, the knowledge of the exact internal mechanisms resulting in these device forces is lacking, limiting insight and predictive accuracy in device design. This study develops a generic finiteelement (FEM) model using commercially available software to better understand force generation and aid in precision device design, thus speeding up the overall design and implementation process for uptake and use. The model is applied to 17 experimental HF2V devices of various sizes. The highly nonlinear analysis is run using the software with automatic increments to balance higher accuracy and computational time. The total force output is sum of the friction forces between lead and steel and the contact pressure forces acting between moving shaft and displaced lead. FEM forces and plots of the 17 devices are compared with experimental device forces and test plots. The errors from force comparison for all 17 devices range from −8% (overprediction) to þ39% (underprediction) with a mean absolute error of 7.6% and a signed average error of 4.7%, indicating most errors were small. In particular, the standard error (SE) in manufacturing is SE ¼ AE14%. Overall, 13 of 17 devices (76%) are within AE1 SE of 14%; 3 of 17 devices (18%) are within AE2 SE (AE28%), and the last has −39% error, which is within AE3 SE ¼ AE42%. These results show low errors and a distribution of errors compared with experimental results that are within experimental device construction variability. The overall modeling methodology is objective and repeatable, and thus generalizable. The results validate the overall approach with relatively very low error, providing a general modeling methodology for accurate design of HF2V devices.

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“…To obtain accurate simulation results, reasonable friction and heat transfer conditions at the billet/tools interfaces should be adopted. The heat transfer coefficient between the billet and porthole die was set to be 3000 W/m 2 ·°C [ 22 , 23 ]. When the extrusion temperature was greater than 400 °C, the friction type at the interface between the billet and porthole dies (except die bearing) was considered to be sticking friction [ 24 ].…”

Section: Porthole Die Design and Simulation Proceduresmentioning

confidence: 99%

Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity

Liu

et al. 2018

Materials

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The design of a porthole die is one of the key technologies for producing aluminum profiles. For an aluminum profile with high length–width ratio and small cavity, it is difficult to control the metal flow through porthole die with the same velocity to ensure the die’s strength. In the present study, the porthole die extrusion process of aluminum profile with small cavity was simulated using HyperXtrude 13.0 software based on ALE formulation. The simulation results show for the traditional design scheme, the metal flow velocity in porthole die at every stage was severely not uniform. The standard deviation of the velocity (SDV) at the die exit was 19.63 mm/s. The maximum displacement in the small mandrel was 0.0925 mm. Then, aiming at achieving a uniform flow velocity and enough die strength, three kinds of die structure modifications for the porthole die were proposed. After optimization, desired optimization results with SDV of 0.448 mm/s at the die exit and small mandrel deflection were obtained. Moreover, the temperature uniformity on the cross-section of die exit, welding pressure, and die strength were improved greatly. Finally, the optimal porthole die was verified by the real extrusion experiment. A design method for porthole die for aluminum with a high length–width ratio and small cavity was proposed, including sunken port bridges to rearrange the welding chamber in upper die, increasing the entrance angle of portholes, introducing the baffle plate, and adjusting the bearing length.

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Simulation of extrusion process of complicated aluminium profile and die trial

Cited by 35 publications

References 12 publications

Building a Case Base for the Non-Conformance Problem Solving in the Aluminum Extrusion Process

Building a Case Base for the Non-Conformance Problem Solving in the Aluminum Extrusion Process

Nonlinear Finite-Element Modeling of HF2V Lead Extrusion Damping Devices: Generic Design Tool

Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity

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