Liquid nitrogen in the industrial practice of hot aluminium extrusion: experimental and numerical investigation

Pelaccia, Riccardo; Reggiani, Barbara; Negozio, Marco; Donati, Lorenzo

doi:10.1007/s00170-021-08422-3

Cited by 6 publications

(7 citation statements)

References 25 publications

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“…The Fig. 1 shows the tooling set composed by the mandrel, die and backer [10]. The mandrel with five portholes was designed to obtain the industrial hollow profile shown in Fig.…”

Section: Experimental Analysismentioning

confidence: 99%

“…In addition, the level of complexity force not only through numerical approaches, but also demands for automated, robust and comprehensive methodologies. If many works have been reported on aluminum extrusion FE (Finite Element) modelling [6,7], stating the robustness and reliability of the approach, only recently Reggiani and Donati [8], and Pelaccia et al [9,10] proposed a comprehensive numerical model for the prediction of the thermal gradient during the extrusion process with nitrogen cooling. In addition, very promising results have already been achieved, by the same authors, by integrating the comprehensive FE model in an optimization platform able to change the channel sections iteratively and automatically along the path [11].…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, in this context, an industrial case study previously investigated [10] has been selected to present and validate the approach. The process parameters and the experimental settings were selected as input for the subsequently numerical analysis.…”

Section: Introductionmentioning

confidence: 99%

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Investigation on the topological optimization of cooling channels for extrusion dies

Pelaccia

2023

Materials Research Proceedings

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Abstract. During the extrusion process, high temperatures are generated, due to friction and deformation works, potentially leading to profile and die defects. Among the suggested solutions aimed at controlling the thermal field of the process, the most accredited one involves the manufacturing of cooling channels at the mating face between the die and a third plate. Despite the proven efficiency of well-designed channels, the main drawback lies in the managing of the many variables involved that strongly affect the cooling efficiency and balancing. In this frame, aim of the work is to investigate the applicability of the topological optimization tool, proposed by COMSOL Multiphysics software, for the design of cooling channels in extrusion dies. To validate the tool, an industrial case study has been selected and results compared between not optimized and optimized cooling solutions.

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“…The Fig. 1 shows the tooling set composed by the mandrel, die and backer [10]. The mandrel with five portholes was designed to obtain the industrial hollow profile shown in Fig.…”

Section: Experimental Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Investigation on the topological optimization of cooling channels for extrusion dies

Pelaccia

2023

Materials Research Proceedings

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“…30 A numerical model of AA6060 extrusion process was carried out to predict and optimize the nitrogen cooling effect in the die. 31 A numerical model is used to optimize the channel design in terms of the cooling efficiency, die heat balance, and reduction of liquid nitrogen consumption. 32 To efficiently install the cooling channels as close as possible to the bearing region, conformal cooling channels manufactured by selective laser melting (SLM) are implemented in the die designs.…”

Section: Introductionmentioning

confidence: 99%

“…To provide extruders and die manufacturers with a numerical tool particularly for the thermal distributions of dies, a FEM model for the extrusion process with the liquid nitrogen cooling system was developed 30 . A numerical model of AA6060 extrusion process was carried out to predict and optimize the nitrogen cooling effect in the die 31 . A numerical model is used to optimize the channel design in terms of the cooling efficiency, die heat balance, and reduction of liquid nitrogen consumption 32 .…”

Section: Introductionmentioning

confidence: 99%

A novel combo‐transmission system of cold energy and electricity for aluminium profile production: Using liquid nitrogen and superconductor technologies

Chen

Jiang

et al. 2022

Energy Science & Engineering

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Aluminium production needs the most energy‐intensive technologies among all the metal processing sectors. During the process of aluminium profile extrusion, the whole production line needs bulk electricity, and the mold inside the extrusion equipment needs robust cold energy for rapid cooling of the metal surface. This paper presents a new combo‐transmission that can simultaneously deliver cold energy together with electricity to the aluminium profile extrusion line. Thanks to the superiority of virtually zero loss and compact size, the powerful superconducting cable is used to replace the conventional copper cable. The entire superconducting cable assembly is fully installed into a cryogenic pipeline and cooled by liquid nitrogen at 77 K. In addition to keeping a favourable cryogenic environment for the superconducting cable, liquid nitrogen can also provide a large amount of cold energy for cooling the metal surface. For a typical 100 MN aluminium extrusion production line, the design and optimization of 10 kA class superconducting cable with the pipeline cooling system for aluminium production are presented in detail. The simulation results and comparisons show that the total energy loss of superconducting transmission is about 46% of conventional copper cable, and the energy saved in a year can be up to about 240.6 MWh. Moreover, the net profit increases almost linearly along with the increases of the extrusion speed when the liquid nitrogen cooling is applied to the 100 MN production line. For the case of 23% increase in extrusion speed, the net profit can be up to 1.48 M$ in a year. Overall, the novel design, technical evaluation, and economic analysis of the combo‐transmission system (cold energy + electricity) can provide a promising solution for future high‐dense aluminium production sectors.

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Numerical simulation and multiobjective optimization of fluid–structure interaction in aluminum extrusion

Pazeto

Pereira

Gomes

2022

Int J Adv Manuf Technol

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Liquid nitrogen in the industrial practice of hot aluminium extrusion: experimental and numerical investigation

Cited by 6 publications

References 25 publications

Investigation on the topological optimization of cooling channels for extrusion dies

Investigation on the topological optimization of cooling channels for extrusion dies

A novel combo‐transmission system of cold energy and electricity for aluminium profile production: Using liquid nitrogen and superconductor technologies

Numerical simulation and multiobjective optimization of fluid–structure interaction in aluminum extrusion

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