• Transactions of Materials Processing
• /
• v.10 no.4
• /
• pp.311-318
• /
• 2001

Porthole die extrusion has a great advantage in the forming of long hollow section tubes. It is difficult to produce long hollow section tubes with complicated section by the conventional extrusion process with a mandrel on the stem Because of the limit of the length of mandrel and the complexity of cross section. Porthole die extrusion is affected by many parameters, such as extrusion ratio, extrusion speed, die geometry, porthole number, bearing length etc. Up to now, most of studies about porthole die extrusion have been investigated by experiments or steady state FE-analysis. However, in this paper, porthole die extrusion is analysed by the unsteady state 3D FE-simulation. And the result of unsteady state analysis is compared with the experimental result. Also, the surface state of extruded tubes are examined for the various process conditions.

• Transactions of Materials Processing
• /
• v.9 no.3
• /
• pp.242-248
• /
• 2000

This paper is concerned with the family of parts that generally feature a central hub with radial protrusions. Radial Extrusion is usually used in order to produce complex parts, which is combined with upsetting and/or forward and backward extrusion. Typical parts that fall into this category include cross pieces for universal joints, key-shaft type parts, tube fittings, and differential gears. In this paper, the forming characteristics of radial extrusion combined with forward extrusion is investigated by comparing the punch and mandrel loads. The design factors during radial extrusion combined with forward extrusion are applied to the simulation to see how much those factors have effect on the forming loads. The rigid-plastic FEM is applied to the simulation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2001.05a
• /
• pp.110-114
• /
• 2001

The welding pressure in porthole die extrusion is affected by the shape of welding chamber. It is very important to increase the welding pressure when the tube is used particulary as the materials of hydroforming processing. The high circumferential stress of the tube would make the welding pressure increase during the porthole die extrusion. In order to increase the circumferential stress, it is necessary to make the billets pass through the narrow gap between the conical die and the conical mandrel. This paper describes the welding pressure by the experiments with the two types of the chamber. One of them is the chamber between the flat die and straight mandrel, and the other one is the chamber between the conical die and conical mandrel. The result of the experiments show that the conical chamber makes the welding pressure increase by the effect of the reducing the diameteres of tube.

• Transactions of Materials Processing
• /
• v.7 no.1
• /
• pp.59-65
• /
• 1998

In this study an attempt was made to simulate the coextrusion process of the cladded finned tube manufacturing by extrusion of plasticine. The effects of the billet and the plate inserted between the ingot and extrusion die on the variation of clad thickness of the extruded tube were studied. The results showed that cladded tube with uniform thickness can be obtained by a proper combination of clad thickness of billet and the plate. The relative strength of the billet and clad materials did not affect significantly on the variation of the clad thickness of the extruded tubes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2000.10a
• /
• pp.74-77
• /
• 2000

Porthole die extrusion has a great advantage in the forming of hollow section tubes difficult to produce by conventional extrusion with a mandrel on the stem. Because of the complicated structure of die assembly, extrusion process as a forming of hollow section tubes has been investigated experimentally Therefore, analytic approaches that are useful in profitable die design and in the improvement of productivity are inevitably demanded Welding strength is affected by many parameters, which are such as extrusion ratio, extrusion speed, die shape, porthole number, bearing length, billet temperature and mandrel shape. In this paper, the parameters, which are such as billet temperature, bearing length and tube thickness, are examined. The welding pressures are examined through 3D simulation of non steady state and compared with experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2006.05a
• /
• pp.333-336
• /
• 2006

A new forming method for metal/ other metal two-layer tubes by multi-billet extrusion (MBE) is introduced. The forming possibilities of two-layer tubes CDA 365(inner)/Al 1100(outer) and Al 2014(inner)/Al 1100(outer) by MBE are investigated according to the given frictional condition and die profile. The results show that two-layer tube composed by two types tube as abovementioned can be manufactured by MBE. Some stated variables in the forming process such as effective stress and normalized pressure at welding surface are analyzed by FEM code ($DEFORM^{TM}$-3D)

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.19 no.9
• /
• pp.77-83
• /
• 2018

Thermoplastic elastomers are being used increasingly throughout industry owing to their superior properties, such as superior elasticity, formability, and recoverability. Currently, research related to thermoplastic elastomers is focused on the development of composite elastomers by combining with various materials and the development of equipment. On the other hand, in the field of small and medium sized companies, it is necessary to study not only the application of these new materials, but also the process conditions that enable the extrusion of thermoplastic elastomers in inexpensive uniaxial screwing equipment. If extrusion is performed in a single screw extruder, it is important to maintain a uniform thickness through process control of the extruder. This study examined the effects of the processing temperature, which is an extrusion process variable, on the formability of a tube in the thermoplastic elastomer TPE-800L uniaxial extrusion process. The nozzle zone temperature is the most important factor in the extrusion of thermoplastic elastomer TPE-800L; the most excellent moldability was confirmed at $165-170^{\circ}C$.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.05a
• /
• pp.347-350
• /
• 2003

The metal forming behavior and defect formation in Ti-6Al-4V tube during hot backward extrusion were investigated. To predict the forming-defects such as shear band, inner cracks or surface cracks, dynamic material model(DMM) including Ziegler's instability criterion and modified Cockcroft-Latham fracture criterion(C-L model) were used. These models were coupled to the internal variables generated from FE analysis. The chilling effect and friction indicated a great influence on the deformation mode of the tube and the formation of surface cracks. The simulation results for the backward extrusion were compared with the experimental observations.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.05a
• /
• pp.227-230
• /
• 2009

The aim of this study was to improve extrudability limit, eliminate welding line and obtain optimum thixoextrusion conditions for manufacturing tubes of 7075 Al wrought alloy. By thixoextrusion, it was possible to improve deformability, control isotropy with extrusion direction, eliminate welding line (seamless) and save cost due to low energy consumption compared with conventional extrusion processes. The welded part was not observed at the welding line area. The grains of thixoextruded tube were homogeneously distributed and equiaxed grains were observed. Therefore, thixoextrusion is the most effective variable for the control of the magnitude of the welding line.

• Transactions of Materials Processing
• /
• v.12 no.6
• /
• pp.566-571
• /
• 2003

The metal forming behavior and defect formation in Ti-6Al-4V tube during hot backward extrusion were investigated. Dynamic material model(DMM) including Ziegler's instability criterion was employed to predict the forming defects such as shear band, inner and/or surface cracks. This approach was coupled to the internal variables generated from FE analysis. The simulation results fur the backward extrusion were compared with the experimental observation. The chilling effect and friction indicated a great influence on the deformation mode of the tube and the formation of surface cracks. The formation of forming defects in the extruded tube was attributed to non-uniform distribution of strain, strain rate and temperatures in the extruded tubes for the given test conditions.