Effect of process parameters on metal flow and dead metal zone in extrusion

• Autorzy: Qamar S. Z. , Pervez T. , Arif A. F. M. , Sheikh A. K.
• Języki publikacji: EN

Abstrakty

EN

Extrusion finds increasingly more frequent and important applications in automobile, aircraft, construction and other industries. Optimization of metal flow is crucially important in both design and manufacture as it directly affects extrusion speed (essential for higher productivity) on the one hand, and mechanical properties and surface finish of the extruded product on the other. It is reasonable to assume that material flow properties, die-workpiece and container-workpiece heat transfer and friction conditions, die profile, and die design all affect metal flow. However, the mechanism of dead zone formation and how it affects metal flow is not understood well enough to forecast with an acceptable degree of accuracy what is actually happening. Predictive numerical models are limited because of this lack of perception of the physics of the process. The current paper presents some results from a study about the behavior of metal flow and dead metal zone in cold extrusion. Experiments have been performed on flat-face dies fabricated from H13 tool steel and heat treated and surface hardened to approximately the same specifications as commercial extrusion dies. Three workpiece materials have been experimented with: Al-6063 as it is the most common aluminum alloy in the construction sector, and pure aluminum and lead for their better extrudability. Extrusions have been carried out at four different speeds. Commercial finite element packages ANSYS and ANSYS-LSDYNA have been used for numerical investigation of the effect of variations in important extrusion parameters.

Słowa kluczowe

EN

extrusion; process parameters; dead metal zone; metal flow

PL

wytłaczanie; parametry procesu; strefa martwa metalu; płynięcie metalu

• Wydawca: Komitet Nauki o Materiałach PAN
• Czasopismo: Archives of Materials Science
• Rocznik: 2007
• Tom: Vol. 28, nr 1-4
• Strony: 118--123
• Opis fizyczny: Bibliogr. 7 poz., rys.

Twórcy

autor

Qamar S. Z.

autor

Pervez T.

autor

Arif A. F. M.

autor

Sheikh A. K.

• Mechanical and Industrial Engineering Department, College of Engineering, Box 33 Sultan Qaboos Al-Khodh 123, Saudi Arabia,

Bibliografia

• [1] J. Kusiak, W. Libura, M. Pietrzyk, W.Z. Misiolek, Application of the Finite Element Technique to the Simulation of the Aluminum Extrusion Process, Proceedings of the 6th International Aluminum Extrusion Technology Seminar, Chicago, 1, 1996, 361-367.
• [2] I. Stambler, Extrusion Research Enabling Production of All-Aluminum Cars, Research and Development 39/5 (1997) 39-42.
• [3] J.A. Schey, Introduction to Manufacturing Processes, Thirth Edition, McGraw-Hill, New York, 2000.
• [4] M. Bauser, G. Sauer, K. Siegert, et al., Extrusion, Second Edition, ASM International, 2001.
• [5] K.P. Groover, Fundamentals of Modern Manufacturing: Materials, Processing, and Systems, John Wiley, New York, 1999.
• [6] S.Z. Qamar, A.F.M. Arif, A. Sheikh, Analysis of Product Defects in a Typical Aluminum Extrusion Facility Materials and Manufacturing Processes 19/3 (2004) 391-405.
• [7] A.F.M. Arif, A.K. Sheikh, S.Z. Qamar, K.M. al-Fuhaid, Variation of Pressure with Ram Speed and Die Profile in Hot Extrusion of Aluminum-6063, Materials and Manufacturing Processes 16/5 (2001) 701-716.