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Lateral extrusion of tailor welded aluminum alloy pipes with a lost core of low temperature melting alloy

Ohashi T., Liu G.

Journal of Achievements in Materials and Manufacturing Engineering

2009

Vol. 32, nr 1

61-65

Purpose: In this paper, the authors employ tailor welded aluminum alloy pipes for lateral extrusion process with a lost core to perform a hollow light-weight-part. Design/methodology/approach: The pipe is welded longitudinally by YAG-laser. “The lateral extrusion process with a lost core (LELC)” consists of lateral extrusion of pipes with a soluble solid core, called the “lost core”, which serves as a plastic mandrel. The process proceeds as follows. First, the pipe cavity is filled with the liquid low temperature melting material composing the lost core. The liquid is then solidified to form the soluble core of the pipe. The material is compressed longitudinally as a composite billet as well as forging, and extruded in the lateral direction. After the pipe is deformed, the lost core is melted and removed. s. The bulge by the LELC is carried out by extruding the material for the lateral direction, however the simple bulge by hydro-forming is done by internal pressure. Findings: The LELC process can make a hollow product having uneven wall thickness without the deformation concentrating on a thinner part of the material, because the circumferential deformation of the material will be performed by its meridian strain. Practical implications: The authors have developed LELC process in which the lost core consists of low-temperature melting alloys and have tried to apply the process to perform bulge process with a tailor-welded pipe having two different wall thickness. Originality/value: Optimum volume distribution is important for light-weight-parts, and employment of tailor-welded blanks is effective technique in sheet metal forming. Combination of employment of hollow shape and tailor-welded blanks seems to be hopeful.

Analytical and experimental study on lateral extrusion of cross fittings with a lost core

Ohashi T., Ito H., Shinozaki K., Ito S., Watari H.

Journal of Achievements in Materials and Manufacturing Engineering

2006

Vol. 18, nr 1-2

399--402

Purpose: The authors discuss deform mechanism of lateral extrusion process with a lost core for cross fittings. Outline of the is as follows: At first, cavity of pipe, or channel material, is filled up by liquid of low temperaturę melting material, for instances, low temperature melting alloy, ice (or water) and wax. Then low temperature melting material is solidified to be a soluble core of pipe. Authors call this soluble core the ‘lost core [1-4].’ The third, the material is compressed longitudinally as a composite billet, and extruded for lateral direction. After deformation, low temperature melting material is melted and removed. The authors think the process is suitable for production of cross-fittings because such the product has constant sections for lateral direction. Design/methodology/approach: The authors have examined the process with experiments [1] and numerical analysis with ANSYS9.0. Findings: The feature of the process is revealed. Extrusion defect is caused at the center of the cross on the inner wall of the pipe because of volume constancy when the branch diameter close to the initial pipe diameter. In such the case, contact between pipe and die surface is unstable and the branch part is not stretched enough, then it causes wrinkles. In such the case, it is better to provide more pressure against the head of branch projection. Research limitations/implications: In future work, the effect of the relationship amongst mechanical properties of the pipe and lost core is to be examined. In addition, the authors will seek better material for the lost core that is cheaper, easier to remove, clean and safer for the man and environment. Practical implications: Throughout the above research, authors conclude the suggested process is useful for making cross fittings, and the process can be useful on the other hollow products. Originality/value: The above result helps design of the economical process for fittings. The process requires only simple equipments.