A Design Approach of Porthole Die for Flow Balance in Extrusion of Complex Solid Aluminum Heatsink Profile with Large Variable Wall Thickness

Truong, Tat-Tai; Hsu, Quang‐Cherng; Tong, Van-Canh; Sheu, Jer‐Jia

doi:10.3390/met10050553

Cited by 12 publications

(6 citation statements)

References 21 publications

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“…Curtain wall structure (this study) 125 AA7005 I-profile [12] 24 AA6063 Heatsink profile [18] 65 AA6063 Large-size, flat wide, multi-ribs profile [15] 81 AA6060 Large-scale profile [17] 122 AA6063 Solid profile with tips and thin walls [10] 9 AA7075 Hollow square tube [20] 15 AA7075 Non-symmetric hollow profile [19] 23 AA7075…”

Section: Profile Complexity Index (Ci = Dcc/tmin) Materialsmentioning

confidence: 99%

“…They used aluminum 6061 and 7075 as the extruded materials and investigated the effects of pocket shape, depth, location, and bearing length on flow behavior to better understand the effects of these parameters on the extrusion process. Truong et al [17,18] optimized die designs for complex AA6063 aluminum profiles. In their first study [17], they used FEA simulations to refine a specific porthole die design to improve flow balance and reduce stress for complex heatsinks.…”

Section: Introductionmentioning

confidence: 99%

“…In their first study [17], they used FEA simulations to refine a specific porthole die design to improve flow balance and reduce stress for complex heatsinks. Their second study [18] was a broad investigation that employed comparative simulations to assess and optimize three die types (flat, pocket, and spread) for diverse profile requirements. Despite these differing approaches, both studies shared the common goal of improving extrusion efficiency and effectiveness by providing valuable insights for designers and engineers.…”

Section: Introductionmentioning

confidence: 99%

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Analyzing and enhancing the porthole die design for extruding a complicated AA7005 profile

Nguyen,

Truong,

Wang

et al. 2024

Preprint

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Porthole extrusion enables the production of aluminum profiles with intricate cross-sections. It can efficiently shape complex profiles; however, few studies have investigated complex hot extrusions using porthole dies, particularly with 7000-series aluminum alloys. Although 7000-series aluminum alloys are renowned for their superior strength, they have poor extrudability, especially for complex extrusion profiles. Implementing an effective die design is essential for avoiding extrusion defects and maximizing extrusion performance. In this study, a porthole extrusion method for a complex profile was developed for AA7005, a medium-high-strength aluminum alloy. Computer-aided engineering simulations were employed to analyze die strength and forecast the flow of the material. After the first trial with the initial design, the lower die was slightly modified. However, following this minor modification, there were occurrences of material blockages. A major revision of die design was then performed, in which bearing length, die runout, and pocket shape were all adjusted. For validation, extrusion testing was conducted, and the effectiveness of the modifications was determined. Finally, the extrusion processes of the modified and initial die designs were compared, including their metal flow behavior, maximum extrusion forces, and product dimensions. The study highlights a well-rounded methodology that incorporates simulation and empirical results to comprehensively understand the challenges of complicated profile extrusion processes with medium-high-strength aluminum alloy.

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Section: Profile Complexity Index (Ci = Dcc/tmin) Materialsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Analyzing and enhancing the porthole die design for extruding a complicated AA7005 profile

Nguyen,

Truong,

Wang

et al. 2024

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…A longer bearing leads to a greater dimensional accuracy of the profile. In the work [ 19 ], the porthole die for the extrusion of a solid heatsink profile with high wall thickness variation was designed using finite element (FE) simulations. The structure of the die elements effectively influenced the flow behaviour of the metal.…”

Section: Introductionmentioning

confidence: 99%

FEM Numerical and Experimental Study on Dimensional Accuracy of Tubes Extruded from 6082 and 7021 Aluminium Alloys

et al. 2023

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The extrusion of hollow profiles from hard-deformable AlZnMg alloys by using porthole dies encounters great technological difficulties in practice. High extrusion force accompanies the technological process, which is caused by high deformation resistance and high friction resistance in extrusion conditions. As a result of high thermo-mechanical loads affecting the die, a significant loss of dimensional accuracy of extruded profiles can be observed. The different projects of porthole dies for the extrusion of Ø50 × 2 mm tubes from the 7021 alloy were numerically calculated and then tested in industrial conditions by using a press of 25 MN capacity equipped with a container with a diameter of 7 inches (for 7021 alloy and 6082 alloy for comparison). New extrusion die 3 with modified bridge and mandrel geometry and a special radial–convex entry to the die opening was proposed. FEM was applied to analyse the metal flow during extrusion, geometrical stability of extruded tubes and the die deflection. The photogrammetric measuring method was used to evaluate dimensional accuracy of tubes extruded in different conditions and geometrical deviations in porthole dies elements, especially the bridges and the mandrels. Research revealed a high dimensional accuracy of tubes extruded from the 6082 alloy and from the 7021 alloy by using original extrusion die 3, while much higher dimensional deviations were noted for tubes extruded from the 7021 alloy by using extrusion dies 1 and 2, particularly in relation to the circularity, centricity and wall thickness.

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“…However, high pressure is required to use various materials in this process. The porthole extrusion of soft materials such as aluminum [5][6][7][8][9][10] and magnesium [11,12] that are easy to deform and the extrusion of materials with high formability, such as steel [13,14], have been actively studied. However, studies on the tube extrusion of titanium are extremely rare due to the breakage of the dies due to high deformation resistance and the limitation of the equipment capacity.…”

Section: Introductionmentioning

confidence: 99%

Die Design for Extrusion Process of Titanium Seamless Tube Using Finite Element Analysis

Choi

Moon

et al. 2021

Metals

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In this paper, the extrusion process of titanium seamless tubes was studied using several finite element (FE) analyses. First, the finite element result was compared with experimental extrusion data acquired to validate the current analysis. Then, the effect of design parameters of the die shape was numerically analyzed using commercial FE software, Forge NxT, for the metal forming process. Elastic FE analyses were also conducted for dies to analyze the maximum principal stress that affects the early fracture of dies during the extrusion process and the maximum von Mises stress that causes the severe deformation of dies. Consequently, the effect of the corner radius at the exit and land length on the extrusion load and die stress is negligible compared to that of the corner radius at the entrance and die angle. Finally, we suggested a die angle of 60° and a corner radius at the die entrance between 10 and 15 mm as an optimal design for the current extrusion process.

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A Design Approach of Porthole Die for Flow Balance in Extrusion of Complex Solid Aluminum Heatsink Profile with Large Variable Wall Thickness

Cited by 12 publications

References 21 publications

Analyzing and enhancing the porthole die design for extruding a complicated AA7005 profile

Analyzing and enhancing the porthole die design for extruding a complicated AA7005 profile

FEM Numerical and Experimental Study on Dimensional Accuracy of Tubes Extruded from 6082 and 7021 Aluminium Alloys

Die Design for Extrusion Process of Titanium Seamless Tube Using Finite Element Analysis

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