Application of equal channel angular extrusion to semi-solid processing of magnesium alloy

A new method called new strain induced and melt activated (new SIMA) is introduced firstly through using equal channel angular extrusion (ECAE) as strain induced step in SIMA and completing melt activated step by semi-solid isothermal treatment, by which semi-solid billet with fine spheroidal grains with average grain size of 5 μm can be prepared. Comparing with common SIMA, semi-solid processed satellite angle frame components using semi-solid billet prepared by new SIMA have higher room temperature and 393 K high temperature mechanical properties.     

Formability Limit in Containerless (Open Die) Extrusion of Commercial Purity Titanium Rods and Tubes

Containerless extrusion requires far less forces compared to conventional direct extrusion of rods and tubes due to the elimination of container wall-billet friction. But the strains that can be imparted are less in the former due to the unsupported billet which gets upset first if the axial stress exceeds yield stress of the billet material. If this stress is equal to yield stress, it corresponds to the limit of the process of pure containerless extrusion. It is found that this limit strain as predicted by theory is far less compared to what is observed experimentally. This discrepancy is explained on the basis of heating that takes place in the deformation zone due to ideal, frictional, and shear work done in carrying out the extrusion process.     

Finite element analysis of plastic deformation in variable lead axisymmetric forward spiral extrusion

A modified axisymmetric forward spiral extrusion (AFSE) has been proposed recently to enhance the strain accumulation during the process. The new technique is called variable lead axisymmetric forward spiral extrusion (VLAFSE) that features a variable lead along the extrusion direction. To assess the effect of design modification on plastic deformation, a comprehensive study has been performed here using a 3D transient finite element (FE) model. The FE results established the shear deformation as the dominant mode of deformation which has been confirmed experimentally. The variable lead die extends strain accumulation in the radial and longitudinal directions over the entire grooved section of the die and eliminates the rigid body rotation which occurs in the case of a constant lead die, AFSE. A comparison of forming loads for VLAFSE and AFSE proved the advantages of the former design in the reduction of the forming load which is more pronounced under higher frictional coefficients. This finding proves that the efficiency of VLAFSE is higher than that of AFSE. Besides, the significant amount of accumulated shear strain in VLAFSE along with non-axisymmetric distribution of friction creates a surface feature in the processed sample called zipper effect that has been investigated.     

Axi-symmetric forward spiral extrusion, a kinematic and experimental study

A modified axi-symmetric forward spiral extrusion process has been proposed here to allow for a near zero area reduction process. The axi-symmetric forward spiral extrusion, AFSE, can be carried out through a die with a number of engraved spiral grooves. This paper investigates the kinematics of the AFSE process. A velocity field is derived using principle of mass conservation along the extrusion axis. The proposed model has been developed to calculate strain components in the deformation zone during the process. An experimental method has been designed which uses composite lead samples with embedded copper wires to trace the strain path to verify the proposed velocity field. A good agreement between experimental results and the proposed analytical model was observed. The proposed velocity field, verified by experimental results, shows that the deformation develops away from the AFSE die-sample interface. A linear gradient of velocity in the radial direction was observed which is in good agreement with the proposed velocity field. Based on the estimated strains, velocity gradient, and nearly no change in sample cross section during AFSE, the process seems to have good potential for application as a new severe plastic deformation process in both continuous and batch modes.     

复杂截面型材力控制拉弯成形数值模拟分析

复杂截面挤压型材的高精度拉弯成形是制造框架式车身的关键技术.本文基于动态显式有限元软件PAM-STAMP,针对一种典型的框架武车身用复杂截面挤压型材,对其力控制方式的直进台面式拉弯成形进行了数值模拟研究,对比分析了两种截面形状的型材截面畸变和回弹随补拉力增大的变形规律,并得到了摩擦系数对成形精度的影响.数值模拟结果表明,增加型材截面的变形刚度,可以显著地减小截面畸变和回弹;增加补拉力,增大了截面畸变但减小了回弹;增大摩擦系数,截面畸变量减小而回弹增加.     

Metal flow behaviour of wide flat bar in the spreading extrusion process

Abstract

To examine metal flow behaviour experimentally in the spreading extrusion process, a round billet is spread by means of a spread ring and extruded through a die opening wider than the internal diameter of the container. In spreading extrusion, the extrusion load is reduced by about 30% in comparison with basic extrusion. However, the metal flow balance in spreading extrusion worsens, because of the high frictional force generated at the interface of the billet and spread ring during the filling process. When the profile is wide or when spread ring height is low, the geometry of the plastic deformation zone on the die face changes from an ellipse into a figure of eight at the wide zone at both ends of the die opening. As a result, the metal flow balance markedly worsens, due to an increase in the size of the plastic deformation zone and frictional resistance acting on the spread ring wall.     

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.     

颤振激励条件下的反挤压有限元模拟分析

目的 针对“难成形零件”提出的电液颤振挤压成形技术,理论研究颤振对冷挤压成形的影响规律。方法 通过离散化处理颤振速度,对挤压筒和顶杆分别施加颤振激励,利用DEFORM-3D软件有限元模拟,分析比较不同颤振激励下的行程载荷、摩擦力、速度场和应力应变场。结果 在挤压成形过程中,材料流动规律会由于颤振激励的存在而发生改变,在局部区域,材料流动速度较传统挤压时有较大提高;当颤振最大速度小于挤压速度时,颤振对挤压力、摩擦力、等效应力和等效应变的影响并不显著,当颤振最大速度大于挤压速度时,颤振可降低挤压力与摩擦力,改变等效应力和应变分布,但并不影响最大等效应力值。结论 颤振激励影响材料流动规律,对挤压力、摩擦力和应力应变场的影响存在一个拐点,为电液颤振冷挤压成形技术的推广应用提供了一定理论依据。     

HDPE熔体连续挤出自增强的研究：（Ⅱ）自增强试样横截面？…

ＤＳＣ分析表明,熔体连续挤出自增强ＨＤＰＥ片材表层的自增强程度要比芯部的高。借助楔形收敛流道内熔体流场,与温度的分布规律,可知,熔体温是导致自增强试样横截面民自增强程度不均匀的主要原因。     

The role of back-pressure in equal channel angular extrusion

Equal Channel Angular Extrusion (ECAE), developed and patented in Russia by Segal in 1977, has become in the last few years a very popular tool for studying the evolution of microstructure and properties under severe plastic deformation. It is believed that the strain-stress characteristics are uniform in a cross-section of the billet and this uniformity of the stress-strain distribution ensures the uniformity of microstructure and mechanical properties in ECAE processed billet. However, some experimental data such as the fracture of the extruded billet, which is initiated at the inner surface of the sample, has caused doubts about uniformity of stress-strain distribution. This non-uniformity has been proved recently by Finite Element Simulation.This paper reviewed our results from over six years of work using a unique machine for ECAE with computer controlled back-pressure and velocity of the backward punch. Theoretically back-pressure has been introduced in the earlier papers of Segal. However, practically back-pressure has not been widely used or often used in a primitive form of the consequent extruded sample and its role has not been understood.     

Hot Hydrostatic Extrusion of Mechanically Alloyed Al-4.9Fe-4.9Ni Powders

Al-4.9 Fe-4.9 Ni alloy powders have been synthesized by mechanical alloying. The rnechanically alloyed powders are consolidated by hot hydrostatic extrusion. The results show that extrusion tempereture. extrusion ratio and lubricant have great effects on the quality of extruded rods and their mechanical properties, The mixture of graphite and glass powders as lubricant can prevent the oxidization of cold compacted billet by cladding the billet with this lubricant before heating. This technique greatly simplifies the conventional densification process of powders     

Optimal tool angles for equal channel angular extrusion of strain hardening materials by finite element analysis

Equal channel angular extrusion (ECAE) is a novel deformation process capable of imparting a large amount of plastic strain to bulk material through the application of uniform simple shear. ECAE die geometry, material properties and process conditions influence the shear deformation behavior during extrusion that in turn governs the microstructure and mechanical properties of the extruded materials. Finite element analysis, the most appropriate technique was used to analyze the deformation behavior of extruded materials without neglecting important and realistic factors like strain hardening behavior of the material, frictional conditions and speed of the process. In this study the deformation behavior of material, dead zone/corner gap formation and strain homogeneity achieved in the samples during ECAE were studied by using commercial finite element code Abaqus/Explicit. The influence of tool angles, strain hardening behavior of material and friction between the billet and die was considered for simulations. Results showed that the optimal strain homogeneity in the sample with lower dead zone formation, without involving any detrimental effects, can be achieved with channel angle of 90° and outer corner angle of 10°.     

The Occurrence of Ideal Plastic State in CP Titanium Processed by Twist Extrusion

This paper deals with the analysis of strength and plastic characteristics of commercially pure (CP) titanium as a function of equivalent plastic strain accumulated during Twist Extrusion (TE) process. It is shown experimentally that multipass TE leads to the saturation of the following characteristics of the material: yield stress, reduction in area, elongation to failure, and uniform elongation. This fact indicates the occurrence of an ideal plastic state in the processed material. The threshold value of accumulated plastic strain for ideal plastic behavior of CP titanium during TE is defined. The strain state and mechanical properties of CP titanium billets processed by TE are studied. An explanation for the hardening on the axis of a billet during TE is offered. The analysis of deformation modes on the billet axis during TE and High Pressure Torsion is carried out. It is shown that the differences in strain state on the axis are caused by the difference in symmetry of these processes.

     

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...     

Billet quenching extrusion process as efficient and reliable replacement for conventional extrusion of Al–Cu alloys

Abstract

In order to eliminate the separate solution soaking treatment used for Al–Cu extrudates, the influence of billet heat treatments before the extrusion process on a precipitation hardenable AlCu6PbBi (AA2011) alloy was studied. The hot deformation behaviour of the alloy was studied using compression tests. A comparison of the conventional extrusion process, press quenching and billet quenching (BQ) before extrusion was made in production on a 35 MN press. The transformation kinetics was studied by heat treating homogenised samples in salt baths. The mechanical testing, using tensile tests and the Brinell hardness test, and a microstructural investigation, using light and TEM microscopy, revealed that extrusion using the billet quenching process results in the formation of extrudates with similar mechanical properties, hardness and microstructures as those produced using conventional technology. In the extrudates produced by BQ a supersaturated solid solution is formed directly after cooling in a standing water wave, which makes BQ an efficient and reliable substitute for the conventional extrusion process.     

Extrusion upsetting multiple processing in sandglass die

Abstract

A new method of producing ultrafine grain sizes, known as extrusion upsetting multiple processing in sandglass die or sandglass extrusion, has been investigated using a Zn–5Al (wt-%) alloy. Since the shape of the test billet can remain unchanged after sandglass extrusion, the billet can be extruded repeatedly in order to obtain a large plastic strain. Ultrafine grain size can be achieved in the billet material due to the large plastic strain and dynamic recrystallisation during sandglass extrusion. The process technology, and the microstructures, superplasticity, and microhardness of the test material after sandglass extrusion have been studied. The experimental results show that equiaxial ultrafine microstructures can be introduced into the bulk test material during sandglass extrusion and high strain rate superplasticity can be realised.     

Twist-channel angular pressing: effect of the strain path on grain refinement and mechanical properties of copper

Substructural characteristics of Cu (99.97%) were examined after the Twist channel angular pressing (TCAP) process carried out at ambient temperature. Grain refinement efficiency and resulting thermal stability were evaluated after three passes with respect to utilization of various strain paths. Results were obtained using light microscopy and X-ray diffraction methods; Mechanical properties of extruded materials were also tested. Thermal stability was studied after application of three annealing cycles. Based on the findings, Bc route is the most efficient strain path with respect to the grain refinement; higher speed of extrusion (10 mm/s) corresponds with suppression of the static recrystallization. Measured strength, obtained after three passes (route A), achieved values around 440 MPa homogeneously along the cross section of the extruded material. Homogeneity of deformation was also confirmed by micro-hardness tests. The grain size, determined after three passes, averaged out 1.2 μm. Application of TCAP (three passes) brought markedly homogeneous deformation throughout the processed sample in comparison with classical ECAP process.     

纯铜粉末包套挤扭成形致密的灰色预测与优化

以横截面扭转角α、螺旋角β、摩擦因子、挤压速度、初始相对密度为因子,建立正交试验设计方案,对纯铜粉末材料进行一道次包套扭挤数值模拟,以获得的平均等效塑性应变εm、平均最大损伤值δmax、平均相对密度ρm作为优化设计目标,运用追踪点法和灰色系统理论的灰色关联度优化工艺参数,使设计目标值达到等效应变最大、最大损伤值最小、相对密度最大。模拟验证结果表明,运用多目标优化参数进行挤扭成形能使纯铜粉末体变形材料迅速地形变累积,最大损伤值显著地减小,致密效率高,提高了材料综合质量。     

Plastic flow of aluminium extruded under complex conditions

Abstract

This paper describes the extrusion process of aluminium in which cyclic changes of the strain path are induced in the natural deformation zone of the extruded piece of metal, through reversible rotation of the die (patented KOBO metal forming process). Such a procedure allows significant reduction in the extrusion force, as well as in the global mechanical work needed for the extrusion of a rod when compared with the conventional process. Macro- and microstructural observations of the products and microhardness and tensile tests show that cyclic changes in the strain path cause a reduction in the differences in the rate of plastic flow in the particular microvolumes of the metal, and lead to structural homogenisation. This process also causes a significant improvement in the plasticity of the extruded rod and a reduction in its work hardening.     

转模挤压成形过程的变形机理研究

针对低塑性合金挤压成形时所需能耗大、材料利用率低等问题,提出了对凹模施加转动的成形新工艺———转模挤压成形技术,并设计了特殊的凹模结构.与芯模转挤压仅适于圆截面制品相比,对凹模施加转动可有效地避免异型截面制品挤出成形时引起的垂直模口部位轴向的＂切断＂等难题.数值模拟及理论分析表明：与普通挤压相比,凹模转挤压成形中塑性区...