Finite Element Model Prediction of Charge Weld Behaviour in AA6082 and AA6063 Extruded Profiles

Negozio, Marco; Pelaccia, Riccardo; Donati, Lorenzo; Reggiani, Barbara; Pinter, Tommaso; Tomesani, Luca

doi:10.1007/s11665-021-05752-x

Cited by 9 publications

(3 citation statements)

References 22 publications

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“…where is the flow stress, the strain, the strain rate, T the temperature (K) and A, m1-m9 the material parameters to be regressed over experimental trials. These material parameters were taken from [10] The friction conditions between workpiece and tools were taken from [10]. The optimized default values for extrusion are reported in Tab.…”

Section: Numerical and Analytical Investigationmentioning

confidence: 99%

Validation of charge welds and skin contamination FEM predictions in the extrusion of a AA6082 aluminum alloy

NEGOZIO

2023

Materials Research Proceedings

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Abstract. The reduction of scraps related to Charge Welds and Skin Contamination defects is getting an increased industrial attention in order to improve the extrusion process overall efficiency. Recently, FEM simulations allowed the prediction of these defects under different die designs or processing conditions without performing time-consuming and expensive experimental analysis. However, the validation of the FEM codes has not been fully experimentally assessed. In this paper, Charge Welds and Skin Contamination defects were experimentally analysed in the extrusion of a AA6082 aluminum alloy profile produced under strictly monitored processing conditions. The collected data were used to assess the accuracy of the predictions made by using two commercial FEM codes Qform Extrusion UK and Altair HyperXtrude. The final aim of this work is to discuss the reliability of the FEM simulations and to validate their applicability in the industrial field.

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Section: Numerical and Analytical Investigationmentioning

confidence: 99%

Validation of charge welds and skin contamination FEM predictions in the extrusion of a AA6082 aluminum alloy

NEGOZIO

2023

Materials Research Proceedings

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“…1d). The defect contamination starts at the end of an extrusion (negative distance with respect to stop-mark, which is a clearly visible mark on the profile surface generated by the adhesion of the material on the bearing zone in the billet replacement [6,7]) and ends on charge welds at positive values after the stop-mark. The behaviour of the skin defect was studied mostly by experiments: Finkelnburg WD et al [8], Kim YT et al [1] and Jowett C et al [9] studied the billet surface flow to quantify the effect of the process parameters on the inflow of billet skin.…”

Section: Introductionmentioning

confidence: 99%

FEM Analysis of the Skin Contamination Behavior in the Extrusion of a AA6082 Profile

Negozio

Pelaccia

Donati

et al. 2022

KEM

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In the extrusion of aluminum alloys, the skin contamination lead to the scraping of the profile extent in which this defect occurs. In order to optimize the scraping process, extrusion companies and die makers can either perform time-consuming and expensive analyses to experimentally determine the evolution of the defect or rely on predictive methods. Recently, numerical methods, as the Finite Elements, are increasingly used to predict the evolution of the skin contamination, but their accuracy is still uncertain. In this work, an AA6082 aluminum profile of industrial complexity is analysed and the data collected used to validate an innovative method for the prediction of the skin contamination evolution developed using the commercial FEM code Qform®. In addition, the results are used to assess the prediction accuracy of an industrial empirical formula often used by operators.

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“…The description of these defects and practical suggestions on how to avoid them were published in several works [2][3][4][5]. Additionally, the specific defects such as streaking lines [6][7][8], insufficient welding quality [9][10][11][12][13], back-end defect [14][15][16], charge weld propagation [16][17][18][19], surface speed cracking [20,21] defects related to microstructure [22,23] etc. have been investigated in more details using numerical simulations and industrial trials.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Underfilling Defect in Aluminium Profile Extrusion Based on ALE Simulation

Kniazkin¹

2022

KEM

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The paper presents a detailed analysis of metal flow inside the extrusion dies and demonstrates the investigation of the formation of underfilling defects. The stress state in the defect zones has been analyzed by means of simulation based on the Eulerian approach. Based on this, it was found that the mean stress (hydrostatic pressure) is not the only parameter that has to be placed into the criterion to get reliable results. The author proposes a new dimensionless underfilling criterion adapted for Eulerian mesh. It is based on analysis of simulation results obtained by QForm Extrusion FEM software [1] and practical experiments for different types of profiles. This criterion has been approved, and critical values have been obtained using a number of industrial projects from different areas of application.

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Finite Element Model Prediction of Charge Weld Behaviour in AA6082 and AA6063 Extruded Profiles

Cited by 9 publications

References 22 publications

Validation of charge welds and skin contamination FEM predictions in the extrusion of a AA6082 aluminum alloy

Validation of charge welds and skin contamination FEM predictions in the extrusion of a AA6082 aluminum alloy

FEM Analysis of the Skin Contamination Behavior in the Extrusion of a AA6082 Profile

Prediction of Underfilling Defect in Aluminium Profile Extrusion Based on ALE Simulation

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