Fatigue Failure of Extrusion Dies: Effect of Process Parameters and Design Features on Die Life |
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Authors: | S S Akhtar A F M Arif |
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Affiliation: | (1) Mechanical Engineering Department, King Fahd University of Petroleum & Minerals, Dhahran, Saudi Arabia; |
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Abstract: | Analysis of die failure plays an important role in the prediction and prevention of die failure, and subsequently in improving
economics of any metal-forming process. Industrial experience has shown that fracture is the most common mode of failure in
the case of hot aluminum extrusion dies. The purpose of the present work is to implement fatigue damage models in a Finite
Element code for identification of critical process parameters and die design features in the case of fatigue being the dominating
failure mode. For the maximum number of billets extruded by the die before fatigue crack initiation (fatigue life cycles in
extrusion), Morrow’s stress- and strain-life damage models are implemented for axisymmetric flat extrusion die. With the help
of finite element software ABAQUS, extrusion process is simulated and dynamic stress and strain values were obtained by first
identifying the potential fatigue location in the die. The evaluation of applicability of the damage models is done for specific
hot extrusion die made of H13 steels with Al-6063 as billet material. By considering temperature and strain rate as process
parameters and bearing length and fillet radius of the die as geometric features, different simulation runs are performed
to investigate the effect of process and design features on the useful die life. Morrow’s stress life model shows a good correspondence
between computed and actual failure of dies. By establishing correlations of die life with process and design parameters under
different conditions, it was shown that the present investigation is a useful guideline at die design and extrusion process
stages. |
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