IN690合金管热挤压温升与挤压力的研究

温升和挤压力是影响钢管挤压过程的重要指标,利用热模拟实验获得了IN690合金的热加工本构关系,建立了IN690合金钢管热挤压过程的有限元模型.采用正交实验设计的仿真实验系统分析了坯料温度（T b=1000～1200℃）、挤压速度（v=20～200 mm/s）和模具预热温度（T d=300～500℃）对管材成形过程中温升...     

Effect of Temperature and Ram Speed on Isothermal Extrusion for Large-size Tube with Piece-wing

Heat energy change during the extrusion of 7075 aluminium alloy large-size tube with piece-wing in a container was analyzed. Extrusion load vs ram displacement diagrams and exit temperature vs ram displacement diagrams at various speeds were obtained by 3D FEM simulation. Results show that the exit temperature becomes higher as the ram speed and displacement increase. For large-size tube with piece-wing, there is certainly a curve of ram speed decreasing with increasing ram displacement, which enables isothermal extrusion to be achieved. Therefore, an attempt was made to divide the working stroke into five different zones. Each of them has a preset speed that decreases from the ram displacement beginning to the ending. And then, new exit temperature vs ram displacement diagram was obtained by 3D FEM simulation for the five different speeds. It is shown that the variation of exit temperature is very small. Through the above research, a basic method for realizing isothermal extrusion of 7075 large-size tube with piece-wing was obtained, that is, the working stroke was divided into several different zones with a decreasing speed during extrusion, each zones' speed was real-time adjusted on the feedback signal of exit temperature by proportional hydraulic valve through closed-loop control. The engineering experiment verification was carried out on 100 MN aluminium extrusion press with oil-driven double action. The experimental results of the exit temperature agrees with the simulation ones. The achievements of this study may serve as a significant guide to the practice of the relevant processes, particularly for isothermal extrusion. The verified method has been used in the design and manufacture of 125 MN aluminium extrusion press with oil-driven double action.     

VARIATION OF PRESSURE WITH RAM SPEED AND DIE PROFILE IN HOT EXTRUSION OF ALUMINUM-6063

Prediction of extrusion pressure, especially in the case of complex die geometries, is an area of continued research interest. Die complexity, usually defined by “shape factor” (the ratio of the perimeter to the cross-sectional area of the profile), critically affects the flow of metal and the pressure required to extrude a given product. Applied strain rate (related directly to the ram speed of the extrusion press) also alters the product quality significantly. The current paper presents results of an ongoing study about effects of ram speed and die profile on extrusion pressure. Experiments were conducted using dies of different complexity to track the effects of ram speed variation and changing die profiles on extrusion pressure. Al-6063, the most popular commercial variety of structural aluminum, was used as the billet material for all experiments.     

Effect of extrusion stem speed on extrusion process for a hollow aluminum profile

Extrusion stem speed is one of important process parameters during aluminum profile extrusion, which directly influences the profile quality and choice of extrusion equipments. In this paper, the extrusion process of a thin-walled hollow aluminum profile was simulated by means of the HyperXtrude commercial software. Through a serial of numerical simulation, the effects of stem speed on extrusion process, such as metal flow behavior at die exit, temperature distribution, extrusion force, and welding pressure, have been investigated. The numerical results showed that there existed an optimum value of stem speed for flow velocity distribution. With the increasing stem speed, the temperature of the extrudate and required extrusion force increased, and the welding quality of extrudate would be improved. Through comprehensive comparison and analysis, the appropriate stem speed could be determined for practical extrusion production. Thus, the research results could give effective guideline for determining initial billet and die temperature and choosing the proper extrusion press in aluminum profile industry.     

The Decreasing of the Extrusion Time with Varying Ram Speed

In the extrusion process, friction and workpiece deformation usually cause an increase in the temperature of the extrudate. During the stroke, this temperature increase may reach a critical level and restrict the ram speed. In this study, extrusion processes, which were conducted under real production conditions, were simulated at different ram speeds using finite element modeling. In this way, the maximum workable constant ram speed was determined according to a defined critical extrusion temperature as a reference value. In the next stage, new ram-speed models were developed as alternatives to the maximum-workable, constant ram speed. The results showed that the time taken to extrude could be significantly shortened by using these models.     

Finite Element Simulations of Four-holes Indirect Extrusion Processes of Seamless Tube

Finite element simulations are performed to investigate the plastic deformation behavior of Ti-6Al-4V titanium alloy during its indirect extrusion through a four-hole die. The simulations assume the die, mandrel and container to be rigid bodies and ignore the temperature change induced during the extrusion process. Under various extrusion conditions, the present numerical analysis investigates the effective stress and profile of product at the exit. The relative influences of the friction factors, the temperature of billet and the eccentricity of four-hole displacement are systematically examined. The simulations focus specifically on the effects of the friction factor, billet temperature and eccentricity ratio of the four-hole die on the maximum load and effective stress induced within the billet and the taper angle of the extruded tubes. The simulation results provide a useful insight into the optimal processing conditions for the four-hole indirect extrusion of seamless titanium alloy tubes.     

Effect of preheat modification on extrusion characteristics of aluminium alloy 2014

Abstract

An extrusion billet is usually homogenized, cooled, and preheated for extrusion by either gas or induction heating. The metallurgical structure of the billet may be modified by a solution treatment during the preheat cycle. In this paper experiments to determine the effect of a solution treatment step during the preheat cycle are described. Torsion tests were performed to establish the optimum preheat cycle and to determine the effect of the modified sequence on the constitutive relationships of the material. Subsequent extrusion tests confirmed that significant increases in ram speed could be obtained and the permissible working area of extrusion limit diagrams could be enlarged by the modified preheat.

MST/122     

实心边框铝型材挤压数值模拟与模具结构优化

目的针对汽车用某实心边框铝型材出口流速不均匀的现象,改进模具的工作带、阻流块和促流角结构。方法运用专业铝型材挤压成形有限元软件系统,对型材的挤压过程进行分析,模拟稳态挤压成形过程,以速度相对差作为衡量速度均匀程度的指标。结果初始模具结构挤出的型材流速不均匀。通过改变工作带长度、增设阻流块以及增加促流角的方法,使得模具出口处的金属流速变得均匀。结论改进后模具所受的压力更小,可以减小模具的磨损,增加模具寿命,模拟结果与实验吻合。     

Extrusion Processing of High-Strength Al Alloy 7055

The effects of a combination of extrusion processing parameters and aging schedules on the microstructure and mechanical properties of the 7055 Al alloy were investigated. A safe extrusion processing zone is determined through a limit diagram constructed over the experimental initial billet temperature ranging from 380° to 420°C, extrusion ratio from 10:1 to 40:1, and the ram speed ranging from 1 to 15 mm s^-1. Microstructural characterization of as-extruded, solution-treated, and artificially-aged materials was carried out using polarized light microscopy (for grain structure) and transmission electron microscopy (for precipitate morphology). A combination of hardness and tensile tests was used to evaluate mechanical properties. It is shown that in 7055 Al alloy, the optimization of alloy composition, extrusion processing parameters, and peak aging treatment results in reproducible tensile properties of 0.2% P.S. = 725 MPa, UTS = 750 MPa, and % elongation = 12.9. In order to improve the stress-corrosion resistance of peak aged material, retrogression and reaging (RRA) temper was established. A strength-electrical conductivity relationship has been established for the RRA temper between 36% and 37% International Annealed Copper Standard (IACS) electrical conductivity to enable selection of suitable combination of properties.     

Optimization of Process Parameters of Hot Extrusion of SiC/Al 6061 Composite Using Taguchi's Technique and Upper Bound Technique

Significance of improving the material processing techniques for SiC/Al composite has been felt due to its enormous application in various key industries. In this research study, SiC reinforced that Al 6061 composite has been developed specially through stir casting route and the same was admitted to hot extrusion process to convert the round geometry into the hexagonal section. Totally, nine experiments were conducted based on L9 orthogonal array emphasized by Taguchi's technique, and the optimum levels were predicted based on the average response graph method. During the experiments, ram speed, temperature of the billet, and a friction between the die and the billet were considered as the process variables, thereby considering the extrusion force as the response variable. Additionally, the analysis of variance has been applied to determine the most significant factor to influence the response. At last, confirmation test was carried out to validate the results of the optimized model. In order to enhance the degree of validation, very famous analytical method of the upper bound technique was also employed to compare the results of the optimized model. Results of the upper bound technique and confirmation test were deviated in zero tolerance with the predicted one.     

Extrusion modelling of 6061 aluminium alloy and particle reinforced MMCs

Abstract

Extrusion modelling was performed for 6061 aluminium alloy and three particle reinforced MMCs (10%Al₂O₃/6061, 15%SiC/6061, 20%Al₂O₃/6061) using constitutive equations previously obtained from torsion test data. In applying the finite element software DEFORM, suitable heat transfer, friction, and velocity boundary conditions were chosen based on a direct extrusion press. Simulations were run for various extrusion conditions and the outputs for the four materials were compared. The simulation results were validated by comparison with real life extrusions and modelling of other researchers. The results showed that an increase in billet temperature, a reduction in ram speed, or a reduction in extrusion ratio had the effect of reducing the ram load. In consequence, extrusion conditions could be selected so that extrusion of the composite was carried out with the same peak ram load as the alloy.     

Modelling of paste flows subject to liquid phase migration

Particulate pastes undergoing extrusion can exhibit differential velocities between the solid and liquid phases, termed liquid phase migration (LPM). This is observed experimentally but understanding and predictive capacity for paste and extruder design is limited. Most models for LPM feature one‐dimensional analyses. Here, a two‐dimensional finite element model based on soil mechanics approaches (modified Cam‐Clay) was developed where the liquid and the solids skeleton are treated separately. Adaptive remeshing routines were developed to overcome the significant mesh distortion arising from the large strains inherent in extrusion. Material data to evaluate the model's behaviour were taken from the literature. The predictive capacity of the model is evaluated for different ram velocities and die entry angles (smooth walls). Results are compared with experimental findings in the literature and good qualitative agreement is found. Key results are plots of pressure contributions and extrudate liquid fraction against ram displacement, and maps of permeability, liquid velocity and voids ratio. Pore liquid pressure always dominates extrusion pressure. The relationship between extrusion geometry, ram speed and LPM is complex. Overall, for a given geometry, higher ram speeds give less migration. Pastes flowing into conical entry dies give different voids ratio distributions and do not feature static zones. Copyright © 2007 John Wiley & Sons, Ltd.     

Extrusion processing of Al–Li–Mg–Zr alloy

Abstract

The hot deformation behaviour of an Al–Li–Mg–Zr alloy was characterised in hot torsion and extrusion. The alloy was found to have similar hot ductility to existing high strength aluminium alloys, but this could be maintained at higher temperatures. Billets were extruded over a range of process conditions and a limit diagram was constructed for surface cracking. All the extrusions were found to be partially recrystallised after deformation, but the volume fraction of recrystallisation was a strong function of billet temperature and extrusion ratio. In addition, the unrecrystallised areas contained a recovered substructure where the subgrain size was inversely proportional to the temperature compensated strain rate. The as extruded structure was retained during solution treatment and as a result final mechanical properties were strongly dependent on the extrusion conditions. The use of high billet temperatures and low extrusion ratios gave the best combination of strength and toughness.

MST/839     

In-process rheometry as a PAT tool for hot melt extrusion

Real time measurement of melt rheology has been investigated as a Process Analytical Technology (PAT) to monitor hot melt extrusion of an Active Pharmaceutical Ingredient (API) in a polymer matrix. A developmental API was melt mixed with a commercial copolymer using a heated twin screw extruder at different API loadings and set temperatures. The extruder was equipped with an instrumented rheological slit die which incorporated three pressure transducers flush mounted to the die surface. Pressure drop measurements within the die at a range of extrusion throughputs were used to calculate rheological parameters, such as shear viscosity and exit pressure, related to shear and elastic melt flow properties, respectively. Results showed that the melt exhibited shear thinning behavior whereby viscosity decreased with increasing flow rate. Increase in drug loading and set extrusion temperature resulted in a reduction in melt viscosity. Shear viscosity and exit pressure measurements were found to be sensitive to API loading. These findings suggest that this technique could be used as a simple tool to measure material attributes in-line, to build better overall process understanding for hot melt extrusion.     

Fracture life prediction and sensitivity analysis for hollow extrusion dies

It has been reported in literature that extrusion dies most often fail by fatigue fracture. Experimental studies have shown that cracks pre‐exist in dies because of various factors including machining, heat treatment and surface hardening. High levels of repeated mechanical and thermal loads result in crack propagation leading to ultimate fracture failure. In an earlier work by the authors, a simplified approach of plate‐with‐edge‐crack was used to develop a fracture mechanics based fatigue life prediction model for tube dies. In the current work, extrusion die is modeled as a pressurized‐cylinder‐with‐internal‐crack, a more realistic approach for a hollow (tube) die. Stochastic nature of various fatigue‐related die parameters has been used to reflect their variability. Monte Carlo simulation has been performed to forecast fracture failure of extrusion dies under a given set of operating conditions and mechanical properties. Predicted mean‐time‐to‐failure is quite close to actual average extrusion die life data from the industry. Using tube die as a basis, fracture life of other hollow profiles can be estimated through their shape complexity values. Analysis has also been carried out to evaluate how sensitive fracture life of hollow extrusion dies is to material and process parameters. Major findings are that die life is highly sensitive to initial crack size, wall thickness, profile outer diameter and billet length; moderately sensitive to Paris constant and extrusion ratio; and only slightly sensitive to fracture toughness and ram speed. These results can contribute to a deeper understanding of the factors responsible for fracture failure of an extrusion die exposed to thermo‐mechanical fatigue environment.     

Influence of the process setup on the microstructure and mechanical properties evolution in porthole die extrusion

Industrial needs are becoming always more complex pushed by an ever more demanding market and an increasingly fierce competition. Innovation and new products are the way forward if customers’ attention has to be captured. On this direction, extrusion processes can be properly designed for the manufacture of complex shape parts. Furthermore, taking into account the current requirements related to the reduction of weights and volumes for fuel saving in the automotive field, the production of components with thinner thickness is increasingly on demand. Therefore, the process complexities have been growing up but, at the same time, companies have to assure quality and productivity in a more and more competitive scenario.In this work, porthole die extrusion was investigated and an “I” shaped section with the welding line in the middle of the tongue was the chosen profile. Different extrusion conditions were experimentally analyzed by changing both the profile thickness and the ram velocity; the impact of these variables on the product quality was evaluated by microstructural observations and tensile tests. The aluminum alloy, AA6060, was the investigated material. The die optimization was carried out by numerical analyses for homogenizing the flow velocity at the die exit; the simulations were also utilized for locally calculate the pressure and temperature distributions in the die and at the exit of the bearing zone for a better explanation of the experimental evidences.A wide discussion on the obtained results is here reported.     

Preliminary evaluation of hot extrusion miniaturization

Experiments were conducted to examine the feasibility of hot extruding metals on a miniature scale thus providing a quick and cheap method of studying extrusion in general. Aluminium was successfully extruded using a new miniature hot extrusion rig, producing aluminium wires (maximum diameter 2.6 mm) as opposed to rods. A preliminary comparison of extrusion pressures on the miniature rig and on a larger extrusion press was conducted. The effects of temperature, extrusion speed and extrusion ratio on the extrusion pressure were examined for both miniature and larger scale extrusions. Extrusion speed had little effect on extrusion pressure, because the range of speeds examined was too small (due to speed limitations on the larger extrusion press). Both extrusion sizes generally displayed similar dependencies on temperature and extrusion ratio. However, the extrusion pressures for miniature extrusions were found to be always lower than for the larger scale extrusions. This may have been due the evaluation of parameters in the expression used for strain rate in the comparison. Finite element analysis may prove useful in gaining a fuller understanding of the miniaturization process.     

12 vol%SiCP/2024Al基复合材料热挤压过程有限元模拟与分析

基于MSC.Marc软件平台,建立了含SiC_P体积分数为12%的SiC_P/2024Al复合材料热挤压轴对称刚-塑性热力耦合有限元分析模型。利用该模型对复合材料的热挤压过程进行模拟,分析了热挤压过程中的载荷-行程曲线和材料流动状态,讨论了模具温度及挤压速度对挤压载荷的影响。模拟结果表明,该坯料在挤压比为30∶1、挤压温度为400～450℃、挤压速度为0.1～1.0 mm/s、挤压载荷为4.0 ×106～5.0 ×106N之间能够顺利挤出表面无缺陷的复合材料棒材。最后通过在 700 t水压机上采用相同工艺挤出高质量的复合材料棒材验证该工艺的可行性。     

Effects of ECAE temperature and billet orientation on the microstructure,texture evolution and mechanical properties of a Mg–Zn–Y–Zr alloy

Single-pass equal channel angular extrusion (ECAE) experiments of an extruded Mg–Zn–Y–Zr alloy with an intense initial basal texture were performed in two inter-perpendicular billet orientations and at 473 and 623 K. The study was aimed to determine the effects of ECAE temperature and billet orientation on the microstructure, texture evolution and mechanical properties of the ECAEed alloy. It was found that the grain refinement achieved through the single-pass ECAE in the Orient-I billet orientation (the normal direction (ND) of the extruded plate parallel with the ECAE exit direction) was more effective than that in the Orient-II billet orientation (the ND of the extruded plate perpendicular to the ECAE exit direction). The average grain sizes after ECAE at 473 K were much smaller than those after ECAE at 623 K. The pole figures of the alloy ECAEed at 473 K showed that most of the basal planes in the Orient-I and Orient-II samples were inclined about 40° and 35°, respectively, with respect to the longitudinal direction of the ECAE extrudate. However, for the alloy ECAEed at 623 K, most of the basal planes were parallel with the longitudinal direction of the ECAE extrudate. It was remarkable that the yield strengths of the alloy ECAEed at 473 K were lower than those at 623 K. The peculiar relationship between ECAE temperature and the mechanical properties of the alloy was ascribed to the texture evolution during ECAE.     

State-space representation and optimal control of non-linear material deformation using the finite element method

A state-space model for representing the non-linear material deformation and an optimal control scheme for obtaining desired process conditions in the deforming material are presented in this paper. The formulation is general for various metal-forming processes including forging and extrusion operations. The state variables selected in the formulation are the die/billet contact nodal velocities and the nodal velocities of the critical finite elements of the billet. The control input is the ram velocity, which is determined by using the linear quadratic regulator (LQR) theory to maintain desired strain rates within the selected finite elements. The influence of an optimally designed ram velocity on the deforming material is studied using performance measures. This paper includes the development of the state-space model from non-linear finite element formulation, optimal control strategy and numerical example cases with discussions.