Extrusion of 7075 aluminium alloy through double-pocket dies to manufacture a complex profile |
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| Authors: | Gang Fang Jie Zhou Jurek Duszczyk |
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| Affiliation: | 1. Institute of Forming Technology and Lightweight Construction (IUL), TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany;2. University of Bologna, Department of Industrial Engineering DIN, Viale Risorgimento 2, 40136 Bologna, Italy;1. Mechanical and Mechatronics Engineering Department, University of Waterloo, 200 University Avenue West, Waterloo, ON N2L3G1, Canada;2. Rio Tinto Alcan, Arvida Research and Development Centre, Jonquiere, Quebec G7S4L2, Canada;3. Department of Materials Engineering, The University of British Columbia, 309-6350 Stores Road, Vancouver, BC V6T1Z4, Canada;1. Department of Materials Science and Engineering, Universidad Carlos III de Madrid, Avda. de la Universidad 30, 28911 Leganés, Madrid, Spain;2. IMDEA Materials Institute, C/Eric Kandel 2, Tecnogetafe, 28906 Getafe, Madrid, Spain;1. Engineering Research Center of Continuous Extrusion, Ministry of Education, Dalian Jiaotong University, Dalian 116028, China;2. Dalian Konform Technical Limited Company, China;1. TU Dortmund University, Institute of Forming Technology and Lightweight Construction (IUL), Baroper Strasse 301, D-44227 Dortmund, Germany;2. Lehigh University, Institute for Metal Forming, 5E. Packer Avenue, Bethlehem 18015, PA, USA;1. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710072, China;2. Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China |
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| Abstract: | Low-temperature incipient melting and high deformation resistance of aluminium alloy AA7075 place extraordinary demands on extrusion die design and process optimization, especially when the shape of the extrudate is complex. The present case study was aimed at combining the considerations on die design and process optimization for the alloy to manufacture a complex solid profile with large differences in wall thickness, by means of 3D FEM simulation and experimentation instead of the traditional trial and error approach. The effects of die bearing length and extrusion speed on extrudate temperature and extrusion pressure were predicted. The results of the simulations clearly indicate that for AA7075 extrusion speed has a strong effect on extrudate temperature and the latter largely determines the surface quality of the extruded profile. A longer die bearing allows more heat to dissipate from the extrudate to the colder die and leads to a greater extrudate dimensional accuracy. The effects of die bearing length and extrusion speed on extrusion pressure are however insignificant. Thus, the extrusion throughput is mainly limited by the extrudate temperature rather than extrusion pressure. The case study demonstrates that 3D FEM simulation is a viable predictive tool for both die design and process optimization and the approach is applicable to the extrusion of other alloys for any other extrudate shapes. |
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