Numerical Analysis of a New Nonlinear Twist Extrusion Process

Yalçınkaya, Tuncay; Şimşek, Ülke; Miyamoto, Hiroyuki; Yuasa, Motohiro

doi:10.3390/met9050513

Cited by 9 publications

(6 citation statements)

References 27 publications

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“…The aforementioned topics could be addressed in several published manuscripts. Grain refinement, which may confer greater formability for a wide range of metallic materials due to twist extrusion, was numerically analysed by Joudaki et al [1] and Yalcinkaya et al [2]. Improved PCBN (Polycrystalline Cubic Boron Nitride) tools for milling operations were discussed and experimented on by Wang et al [3], giving an important contribution to the field of the machining of hard materials.…”

Section: Contributionsmentioning

confidence: 99%

Numerical and Experimental Advances in Innovative Manufacturing Processes

Sousa

Safari

2021

Metals

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Section: Contributionsmentioning

confidence: 99%

Numerical and Experimental Advances in Innovative Manufacturing Processes

Sousa

Safari

2021

Metals

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“…There are different approaches to modelling and optimising the TE process [42,43], usually based on FE methods. Calculations and experiments are aimed to obtain high plastic strain and uniform ultrafine grains [21].…”

Section: Twist Extrusionmentioning

confidence: 99%

Advanced Materials and Technologies for Compressor Blades of Small Turbofan Engines

2020

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Manufacturing costs, along with operational performance, are among the major factors determining the selection of the propulsion system for unmanned aerial vehicles (UAVs), especially for aerial targets and cruise missiles. In this paper, the design requirements and operating parameters of small turbofan engines for single-use and reusable UAVs are analysed to introduce alternative materials and technologies for manufacturing their compressor blades, such as sintered titanium, a new generation of aluminium alloys and titanium aluminides. To assess the influence of severe plastic deformation (SPD) on the hardening efficiency of the proposed materials, the alloys with the coarse-grained and submicrocrystalline structure were studied. Changes in the physical and mechanical properties of materials were taken into account. The thermodynamic analysis of the compressor was performed in a finite element analysis system (ANSYS) to determine the impact of gas pressure and temperature on the aerodynamic surfaces of compressor blades of all stages. Based on thermal and structural analysis, the stress and temperature maps on compressor blades and vanes were obtained, taking into account the physical and mechanical properties of advanced materials and technologies of their processing. The safety factors of the components were established based on the assessment of their stress-strength characteristics. Thanks to nomograms, the possibility of using the new materials in five compressor stages was confirmed in view of the permissible operating temperature and safety factor. The proposed alternative materials for compressor blades and vanes meet the design requirements of the turbofan at lower manufacturing costs.

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“…In order to address the limitations of traditional twist extrusion molds with linear deformation geometry (LTE), the nonlinear twist extrusion (NLTE) process was introduced by one of the co-authors of this work, and certain initial experimental observations were made using pure magnesium [46]. Numerical analyses of NLTE demonstrate advantages in the punch force, deformation distribution, strain evolution, and homogeneous plastic strain distribution compared to LTE [47]. Understanding the texture development and changes in material properties during the process can aid in optimizing the process parameters, which is the main purpose of the current work.…”

Section: Introductionmentioning

confidence: 99%

Comparison of Linear and Nonlinear Twist Extrusion Processes with Crystal Plasticity Finite Element Analysis

Şimşek,

Davut,

Miyamoto

et al. 2024

Materials

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The mechanical characteristics of polycrystalline metallic materials are influenced significantly by various microstructural parameters, one of which is the grain size. Specifically, the strength and the toughness of polycrystalline metals exhibit enhancement as the grain size is reduced. Applying severe plastic deformations (SPDs) has a noticeable result in obtaining metallic materials with ultrafine-grained (UFG) microstructure. SPD, executed through conventional shaping methods like extrusion, plays a pivotal role in the evolution of the texture, which is closely related to the plastic behavior and ductility. A number of SPD processes have been developed to generate ultrafine-grained materials, each having a different shear deformation mechanism. Among these methods, linear twist extrusion (LTE) presents a non-uniform and non-monotonic form of severe plastic deformation, leading to significant shifts in the microstructure. Prior research demonstrates the capability of the LTE process to yield consistent, weak textures in pre-textured copper. However, limitations in production efficiency and the uneven distribution of grain refinement have curbed the widespread use of LTE in industrial settings. This has facilitated the development of an improved novel method, that surpasses the traditional approach, known as the nonlinear twist extrusion procedure (NLTE). The NLTE method innovatively adjusts the channel design of the mold within the twist section to mitigate strain reversal and the rotational movement of the workpiece, both of which have been identified as shortcomings of twist extrusion. Accurate anticipation of texture changes in SPD processes is essential for mold design and process parameter optimization. The performance of the proposed extrusion technique should still be studied. In this context, here, a single crystal (SC) of copper in billet form, passing through both LTE and NLTE, is analyzed, employing a rate-dependent crystal plasticity finite element (CPFE) framework. CPFE simulations were performed for both LTE and NLTE of SC copper specimens having <100> or <111> directions parallel to the extrusion direction initially. The texture evolution as well as the cross-sectional distribution of the stress and strain is studied in detail, and the performance of both processes is compared.

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Numerical Analysis of a New Nonlinear Twist Extrusion Process

Cited by 9 publications

References 27 publications

Numerical and Experimental Advances in Innovative Manufacturing Processes

Numerical and Experimental Advances in Innovative Manufacturing Processes

Advanced Materials and Technologies for Compressor Blades of Small Turbofan Engines

Comparison of Linear and Nonlinear Twist Extrusion Processes with Crystal Plasticity Finite Element Analysis

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