Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

Hoque, Sheikh Enamul; Hovden, Sindre; Culic, Stefan; Nietsch, Jürgen A.; Kronsteiner, Johannes; Horwatitsch, Dieter

doi:10.4028/p-qfc820

Cited by 2 publications

(3 citation statements)

References 10 publications

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“…In the case of visco-plastic friction model used at the container-billet and die-billet interfaces, the simulation model underestimated the extrusion force. Hence, sticking friction model was found to be more appropriate at billet-container and billet-portholes [30,45]. Also, visco-plastic friction model with coefficient 0.3 was suitable at die-billet and hence same have been incorporated in the present studies.…”

Section: Meshing and Boundary Conditionsmentioning

confidence: 84%

“…Three dimensional tetrahedral elements were used for porthole & weld chamber mesh and billet, bearing and profile were meshed with three dimensional six-node prismatic elements [45]. The meshed models were subjected to coarser refinement from profile to the billet to reduce the number of elements and required computational time [39].…”

Section: Meshing and Boundary Conditionsmentioning

confidence: 99%

“…Friction at workpiece-die interface influences metal flow, extrusion load, product quality and deformation during extrusion and friction exists at billet-container, die-bearing, porthole-die interfaces [16,36,45]. In this regard, Hoque et al [45] have worked on various friction models and coefficients used for modeling of aluminium extrusion. In this regard, numerical simulations and experimental validation were carried to compare extrusion force during extrusion.…”

Section: Meshing and Boundary Conditionsmentioning

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: 84%

Section: Meshing and Boundary Conditionsmentioning

confidence: 99%

Section: Meshing and Boundary Conditionsmentioning

confidence: 99%

See 1 more Smart Citation

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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Material Flow Visualization for Metal Extrusion on near Industrial Scale

Horwatitsch

Herr²,

Hinterer³

2022

KEM

Self Cite

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In the simulation of bulk forming processes the validation of the applied simulation models is necessary. Then, predictive simulations are possible. A visualisation method is an advanced way to create additional evaluation parameters. In this work, the upscaling of a newly developed non-destructive method from semi-industrial to near-industrial scale for metal extrusion of aluminium alloys is presented. A copper coating, which deforms with the billet material, was applied to one half (in the longitudinal direction) of a cast billet and detected by computed tomography (CT). The copper pattern was applied by a plasma coating technology to determine the deformation of the billet material during the process until the final profile. A detailed analysis of the upscaled method with improved geometric setup shows the superiority of the newly chosen properties enabling a complete determination of strain state also in the profile.

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Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

Cited by 2 publications

References 10 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

Material Flow Visualization for Metal Extrusion on near Industrial Scale

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