FEM study of extrusion complexity and dead metal zone

• Autorzy: Qamar S. Z.
• Języki publikacji: EN

Abstrakty

EN

Purpose: Quality of the extruded product and efficiency of the manufacturing process can be seriously affected by inconsistent metal flow through the extrusion die. Metal flow problems can also significantly reduce die life. Various researchers have investigated the effect of profile complexity on extrusion pressure, product quality, die life, etc. However, the relationship between shape complexity and metal flow through the extrusion die has not been studied in detail. Cold extrusion experiments on some solid profiles and simulations using the finite element method (FEM) have been used in this work to investigate the effect of profile complexity on dead metal zone and metal flow. Design/methodology/approach: Cold extrusion experiments were performed using flat-face dies of different complexities. 3D finite element simulation was carried out using the commercial finite element packages ANSYS and ANSYS-LSDYNA. Findings: Findings of this FEM study are that there appears to be no definite correlation between dead metal zone (DMZ) size and the currently existing definitions of extrusion shape complexity. Factors such as die profile symmetry and extrusion ratio may also play significant role in the formation of DMZ and distortion of metal flow through an extrusion die. Practical implications: The study can be of direct utility in extrusion die design improvement, and reduction of extrusion defects related to metal flow. Originality/value: The paper provides basis for a deeper understanding of the factors involved in the formation and development of dead metal zone (and related metal flow problems) in metal extrusion.

Słowa kluczowe

EN

cold extrusion; solid profiles; shape complexity; dead metal zone; metal flow; simulation (FEM)

PL

wyciskanie na zimno; złożoność kształtu; strefa martwa metalu; płynięcie metalu

• Wydawca: International OCSCO World Press
• Czasopismo: Archives of Materials Science and Engineering
• Rocznik: 2009
• Tom: Vol. 36, nr 2
• Strony: 110--117
• Opis fizyczny: Bibliogr. 18 poz.

Twórcy

autor

Qamar S. Z.

• Mechanical and Industrial Engineering Department, Box 33, Sultan Qaboos University, Al Khoudh 123, Oman,

Bibliografia

• [1] M. Bauser, G. Sauer, K. Siegert (ed), Extrusion, 2nd edition, ASM International, 2001.
• [2] T. Kloppenborg, M. Schikorra, J.P. Rottberg, A.E. Tekkaya, Optimization of die topology in extrusion processes, Advanced Materials Research 43 (2008) 81-88.
• [3] G. Liu, J. Zhou, J. Duszczyk, FE Analysis of metal flow and weld seam formation in a porthole die, Journal of Materials Processing Technology 200/1-3 (2008) 185-198.
• [4] M. Schikorra, M. Kleiner, Simulation-based analysis of composite extrusion processes, CIRP Annals - Manufacturing Technology 56/1 (2007) 317-320.
• [5] M.P. Reddy, Analysis and design optimization of aluminum extrusion dies, Proceedings of the 8th Aluminum Extrusion Technology Seminar, Orlando, USA, 2 (2004) 171-178.
• [6] J.A. Schey, Introduction to manufacturing processes, 3rdedition, McGraw-Hill, New York, 2000.
• [7] P. K. Saha, Aluminum extrusion technology, ASM International, Materials Park, Ohio, 2000.
• [8] K.P. Groover, Fundamentals of modern manufacturing: materials, processing, and systems, 3rd edition, John Wiley, New York, 2006.
• [9] S.Z. Qamar, A.F.M. Arif, A.K. Sheikh, A new definition of shape complexity for metal extrusion, Journal of Materials Processing Technology 155-156 (2004) 1734-1739.
• [10] A.R. Eivani, T.A. Karimi, The effect of dead metal zone formation on strain and extrusion force during equal channel angular extrusion, Computational Materials Science 42 (2008) 14-20.
• [11] H. Sano, T. Ishikawa, N. Yukawa, Y. Yoshida, T. Kaneko, Effect of extrusion mode and die shape on billet skin behavior in aluminum extrusion, Journal of Japan Institute of Light Metals 58/5 (2008) 183-188.
• [12] H.H. Jo, S.K. Lee, C.S. Jung, B.M. Kim, A non-steady state fe analysis of al tubes hot extrusion by a porthole die, Journal of Materials Processing Technology 173/2 (2006) 223-231.
• [13] L. Donati, L. Tomesani, The effect of die design on the production and seam weld quality of extruded aluminum profiles, Journal of Materials Processing Technologies 164- 165 (2005) 1025-1031.
• [14] S.Z. Qamar, A.F.M. Arif, A.K. Sheikh, T. Pervez, Effect of process parameters on metal flow and dead metal zone in extrusion, Proceedings of the 12th International Research/ Expert Conference on Trends in the Development of Machinery and Associated Technology , TMT’2008, Istanbul, Turkey, 2008, 1403-1406.
• [15] R. Ponalagusamy, R. Narayanasamy, R. Venkatesan, S. Senthilkumar, Computer-aided metal flow investigation in streamlined extrusion dies, Materials and Design 29/6 (2008) 1228-1239.
• [16] V. Mandic, S. Bruschi, T. Marinkovic, M. Zivkovic, M. Targa, FEM simulation and elasto-plastic analysis of porthole-die in extrusion of hollow section aluminum tubes, Proceedings of the 8th International Conference on Technology of Plasticity, Verona, 2005, 207-208.
• [17] 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.
• [18] S.Z. Qamar, A.F.M. Arif, A.K. Sheikh, Analysis of product defects in a typical aluminum extrusion facility, Materials and Manufacturing Processes 19/3 (2004) 391-405.