• Transactions of Materials Processing
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• v.16 no.7
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• pp.555-560
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• 2007

This paper shows some achievements at bending of extruded aluminum profiles during the extrusion process. The conventional process for the production of bent profiles involves a successive extrusion, stretching, and bending of the profiles. Conventional bending methods can not meet demands far precision and cost-effective production in some cases, due to cross sectional deformation, irregular decrease of tube wall thickness and a complication of the process design. An estimation of spring-back required for precision of the bending radius can not always be achieved by the over bending of the profile. Since the profile is hot during the bending process, the spring-back phenomenon can be avoided. This means that an additional bending process is not necessary. Consequently, flexible bending can be achieved with cost reduction and quality improvement. Experimental tests were completed to study the relationship between curvature radius of profile and position of guide on the extrusion for vehicle bumper. A7108 is applied as a billet material in order to increase strength. The overall correlation between the experimental and numerical results is good. It is therefore concluded that the present method provides an efficient means for the constant curvature extrusion process.

• Transactions of Materials Processing
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• v.6 no.5
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• pp.446-455
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• 1997

A Combined extrusion operation consists of forward and backward extrusion forming and it is possible to make the process be simple by employing it. But the metal flow pattern induced by the operation is hard to analyze accurately because the flows are non-steady, which have at least two directions dependent upon each other. So engineers in the industrial factories had conducted the two extrusion operations separately. A new process was designed by the industrial expert for forming of an alu-minum preform using the combined extrusion operation. In this study, experiments and finite element analysis was carried out to determine the process parameters. Through the preliminary experiment, it was shown that warm forming condition was more desirable than cold or hot ones. And optimal shape of initial billet could be also determined. From the compatibility test, bonde-lube was chosen as the optimal lubricant and 20$0^{\circ}C$ as the material temperature by the inspection of micro-structure. The operation was simulated by the rigid-plastic finite element method to examine the metal flow. Disap-pearing of dead metal zone was observed as the punch fell down and desirable shape was obtained from the one operation. As a result of this study, 7 operations could be reduced and 225% of material saved.

• Transactions of Materials Processing
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• v.22 no.3
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• pp.143-149
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• 2013

A new finite element model for the hydrostatic extrusion of a biaxial bar is introduced. In this model, a penalty contact algorithm, which is adopted to replace the traction boundary conditions due to the fluid in the container of the extruder, is incorporated into a consistent penalty finite element formulation for the viscoplastic deformation of a work piece during hydrostatic extrusion. Two parameters, introduced in the penalty contact algorithm in this study, a critical penalty contact pressure $P_0$ and a critical penalty contact distance $D_c$, are carefully examined for various process conditions. The proposed finite element model is applied to the hydrostatic extrusion of a Cu-clad Al bar. The extrusion loads and thickness ratios of the clad materials by the proposed model are compared in detail to values from experiments reported in the literature. Finally, it is concluded that the proposed finite element model is useful in practical implementations.

• Transactions of Materials Processing
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• v.13 no.1
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• pp.33-38
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• 2004

A new approach for the design of extrusion die surface of arbitrarily shaped section is presented. In order to generate the extrusion die surface. an automatic surface construction method based on B-spline surface and scalar field theory is proposed. The isothermal lines and stream lines designed in the scalar field are introduced to find the control points which are used in constructing B-spline surfaces. Intersected points between the isothermal lines and stream lines are used to construct B-spline surfaces. The inlet and outlet profiles are precisely described with B-spline curves by using the centripetal method for uniform parameterization. The extrusion die surface is generated by using the cubic curve interpolation in the u- and v-directions. A quantitative measure for the control of surface is suggested by introducing the tangential vectors at the inlet and outlet sections. To verify the validity and effectiveness of the proposed method, automatic surface generation is carried out for extrusion dies of arbitrarily shaped sections.

• Transactions of Materials Processing
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• v.9 no.4
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• pp.362-371
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• 2000

In order to reduce weight of a high-speed railroad vehicle, the main body has been manufactured by hollow section extrusion using aluminum alloys. A porthole die has utilized for the hollow section extrusion process, which causes complicated die geometry and flow characteristics. Design of porthole die is very difficult due to such a complexity. The three-dimensional finite element analysis for hollow section is also an arduous job from the viewpoint of appropriate mesh construction and tremendous computation time. In the present work, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain, is implemented for the analysis of the hollow section extrusion process. In addition, a modified grid-based approach with the surface element layer is utilized lot three-dimensional mesh generation of a complicated shape with hexahedral elements. The effects of porthole design are discussed through the simulation for extrusion of an underframe part of a railroad vehicle. An experiment has also been carried out for the comparison. Comparing the velocity distribution at the outlet with the thickness variation of the extruded part, it is concluded that the analysis results can provide reliable measures whether the die design is acceptable to obtain uniform part thickness. The analysis results are then successfully reflected on the industrial porthole die design.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.614-620
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• 2007

Deformation characteristics and damage evolution during warm backward extrusion of bulk AZ31 Mg alloy were investigated using finite element analyses. AZ31 Mg alloy was assumed as a hardening viscoplastic material. The tensile tests of AZ31 Mg alloy in previous experimental works showed the ductile fracture even at the warm temperature of $175^{\circ}C$. In this study, damage evolution model proposed by Lee and Dawson, which was developed based on the growth of micro voids in hardening viscoplastic materials, was combined into DEFORM 2D. Effects of forming temperature, punch speed, extrusion ratio and size of work piece on formability in warm backward extrusion as well as on mechanical properties of extruded products were examined. In general, finite element predictions matched the experimental observations and supported the analyses based on experiments. Distributions of accumulated damage predicted by the finite element simulations were effective to identify the locations of possible fracture. Finally, it was concluded that the process model, DEFORM2D combined with Lee & Dawson#s damage evolution model, was effective for the analysis of warm backward extrusion of AZ31 Mg alloys.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.689-695
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• 2004

This paper is concerned with the analysis of the forming load characteristics of a forward-backward can extrusion process. The analysis in this paper is extended to the selection of press frame capacity for producing efficiently final product at low cost. The possible extrusion processes to shape a forward-backward can part with different outer diameters are categorized to investigate quantitatively the forming load, forming energy and maximum pressure exerted on the die-material interface. The categorized processes are composed of combined and/or some basic extrusion processes. After the analysis of the forming load characteristics, the frame capacity of press suitable for a selected process could be determined along with securing the load capacity and with considering productivity. In addition, it is also suggested that different load capacities be selected for different dimensions of a part such as the wall thickness in forward direction. The work in this paper could be a good reference for analysis of complex extrusion and selection of proper frame capacity of press to achieve low production cost and thus high productivity.

• Transactions of Materials Processing
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• v.10 no.4
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• pp.302-310
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• 2001

The twisting and extrusion process of the product with involute helical fin from the round billet is developed by the upper bound analysis. The twisting of extruded product is caused by the twisted inclined die surface connecting the die enterance section and the die exit section linearly. In the analysis, the internal shear surface is defined as the curved twisted plane from the twisting of die surface and the shear work is calculated by the consumption of shear energy. The increase rate of angular velocity is determined by the minimization of plastic work. The angular velocity of die exit can be controlled by the land length and the length of inclined die. The alular velocity assums to be increased linearly by the axial distance from the die enterance to the die exit. The results of the analysis show that the angular velocity of the extruded product increases with the die twisting angle, the reduction of area, and decreases with the die length, the friction constant.

• Transactions of Materials Processing
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• v.12 no.2
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• pp.142-150
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• 2003

To construct the extrusion die surface, a B-Spline surface scheme based on the cubic B-Spline curve interpolation method is proposed in the present work. The inlet and outlet profiles are described with B-Spline curves by using the centripetal method for uniform parameterization. The interior control points of surface are generated using the derivative characteristics of B-Spline curve. A complete B-Spline surface is constructed by using appropriate coordinate transformation and knot deletion. In the present study, a quantitative measure for the control of surface is suggested by introducing the tangential vector and inclination angles at the inlet and outlet sections. To verify the validity of the proposed method, automatic surface generation is carried out for the various types of extrusion die surface.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.261-264
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• 2003

Semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Many advantages are associated with this forming process at the condition that the forming operation is performed under appropriate conditions. The thixoforming process, which needs a suspension of a globular, non-dendritic solid phase in the liquid phase, is characterized by three major steps. The first step is casting of billets with a microstructure suited for thixoforming. The second step is reheating of slugs cut from these billets. The third step is injection of the semi-solid slugs into a die. In this paper, the horizontal reheating machine to obtain the optimal conditions suitable for semiu-solid die casting process was used and applied to extrusion material. It is estimated the possibility of application on semi-solid die casting with extrusion material through various results.