FE analysis of extrusion defect and optimization of metal flow in porthole die for complex hollow aluminium profile

Yang, Jie; Zhen-hu, Wang; Liu, Zhiwen; Zhang, Jianming; He, Xiangming

doi:10.1016/s1003-6326(18)64853-8

Cited by 32 publications

(11 citation statements)

References 16 publications

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“…As extrusion is a thermo-mechanical process, thermal boundary conditions are also important in FE simulations. The convection heat coefficient for heat transfer between die and billet was considered 3,000 W m −2 °C [30].…”

Section: Meshing and Boundary Conditionsmentioning

confidence: 99%

“…Numerical simulations were taken up to produce profile with uniform velocity distribution by making design modifications in porthole dies [25][26][27][28]. Research work reported by Zhang et al [29] and Yi et al [30], indicated that friction at selective regions was varied by incorporating baffle plates for controlling of metal flow in order to achieve velocity uniformity in a profile produced by porthole die. Chen et al [31] investigated the effect of eccentricity ratio on standard deviation of velocity (SDV) , second-step welding chamber on SDV and bearing length variation for uniform velocity distribution of extrudate.…”

Section: Introductionmentioning

confidence: 99%

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Numerical and experimental investigations on AA6063 extrudates: effect of number of portholes on extrusion load and weld strength

Ammu,

Padole,

Agnihotri

et al. 2024

Eng. Res. Express

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In aluminium extrusion process, metal flow is greatly controlled by the die geometry and a variety of intricate profiles can be achieved by designing dies of different configurations. In porthole die extrusion, number of portholes used for a profile is often determined by the subjective knowledge of designers. Nevertheless, extrusion load and weld strength of profile produced are not only dependent on extrusion ratio, temperature of deformation but also on the number of portholes along with other die geometry variables. In the present investigation, systematic studies were carried out on three different dies with four ports, three and two ports around die center to extrude profiles of outer diameter 29.4 mm and thickness 2mm. Numerical simulations were carried out for estimation of pressure, temperature, strain, and strain rate parameters in the weld chamber for all the dies, followed by press trials and profiles produced were subjected to wedge expansion test. The results from numerical simulations indicated that pressure generated inside weld chamber increases with number of portholes. The surface plots indicated highest pressure of about 280 MPa for four port hole and about 276 MPa for three ports die and pressure of about 160 MPa was estimated for two port hole die at the entry of weld chamber , which is 65mm from profile end. Similarly, temperature at profile exit was 551 0C for four portholes die and 546 0C for three portholes die and 537 0C for two portholes die. Furthermore, press trials indicated peak extrusion loads of 5241 kN, 4406 kN and 3961 kN respectively for four, three and two portholes die. Thus, the peak extrusion load decreased by about 16 % for three port and about 25 % for two ports die in comparison with four port die. Also, the extruded profiles in wedge expansion test indicated mean compression load of 22.70±0.14 kN in four porthole die, mean compression load 22.29±0.26 kN for three port die and mean compression load of 17.841± 0.27 kN.

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Section: Meshing and Boundary Conditionsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigations on AA6063 extrudates: effect of number of portholes on extrusion load and weld strength

Ammu,

Padole,

Agnihotri

et al. 2024

Eng. Res. Express

View full text Add to dashboard Cite

show abstract

“…Excessive flow of metal also increases the inhomogeneity of metal flow. During extrusion forming, the more uniform the temperature on the cross section of the ingot, the more uniform the material flow during extrusion [11]. Based on this, this paper gives an innovation concept of extrusion optimization model.…”

Section: Introductionmentioning

confidence: 98%

Application of Artificial Intelligence Extrusion Die Model Based on Finite Element Simulation in Decorative Material Aluminum Alloy

Song

Yuan

Wang

2022

Mathematical Problems in Engineering

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At this stage, the varieties and specifications of aluminum profiles continue to increase, and the scope of application continues to expand. The extrusion forming process is the key technology to realize the production of aluminum profiles, and its technological level determines the quality of the profile products and the service life of the mold. However, in actual production, the quality of the die is difficult to guarantee, and it takes multiple die trials and die repairs to produce qualified products. The numerical simulation technology is used to simulate the actual extrusion process, which can track and describe the flow behavior of the metal in real time, reveal the real flow law of the metal, predict the possible defects of the profile during the extrusion process, and adjust the mold structure and process parameters in time. It can not only improve the quality of extruded profiles, but also reduce production costs and shorten the mold production cycle. Based on this, this paper established an extrusion die optimization design model integrating finite element simulation technology and artificial intelligence algorithm. The prediction models were established with the mean square deviation of the section velocity, the maximum extrusion force and the maximum temperature of the section, respectively, and the optimal design of the structure was realized by using the particle swarm algorithm. The experimental results show that the model in this paper can realize the function well, which verifies the validity of the model.

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“…Refs. [ 11 , 12 ] reported that to obtain a uniform metal flow at the die exit, the porthole die was optimized by adding baffle plates on the die insert. After optimization, the concave defects on the profile were remarkably limited.…”

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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FE analysis of extrusion defect and optimization of metal flow in porthole die for complex hollow aluminium profile

Cited by 32 publications

References 16 publications

Numerical and experimental investigations on AA6063 extrudates: effect of number of portholes on extrusion load and weld strength

Numerical and experimental investigations on AA6063 extrudates: effect of number of portholes on extrusion load and weld strength

Application of Artificial Intelligence Extrusion Die Model Based on Finite Element Simulation in Decorative Material Aluminum Alloy

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

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