Low-temperature incipient melting and high deformation resistance of aluminium alloy AA7075 place extraordinary demands on extrusion die design and process optimization, especially when the shape of the extrudate is complex. The present case study was aimed at combining the considerations on die design and process optimization for the alloy to manufacture a complex solid profile with large diff...

Introduction Bar extrusion is a process in which a block of metal (billet) is forced to flow by compression through a tool (die) opening of a smaller crosssectional area than that of the original billet. There are two basic types of bar extrusion: direct and indirect. The most important and common method used is the direct extrusion (Lange 1988). Figure 1 shows the principle of direct bar extru...

In this research, optimization process of axisymmetric extrusion dies is proposed. Plastic zone is analyzed using finite element method in the Eulerian system with flow formulation. The die profiles are defined by Bezier curves with six control points. Two effective functions are considered in this research; standard deviation of the strain rate and the rate of energy consumption during extrusi...

In this paper, an upper bound approach is used to analyze the tube extrusion process through rotating conical dies with large mandrel radius. The material under deformation in the die and inside the container is divided to four deformation zones. A velocity field for each deformation zone is developed to evaluate the internal powers and the powers dissipated on all frictional and velocity disco...

The main objective of this paper is to study the effect of extrusion parameters (extrusion stresses and temperature) and die geometry, i.e. extrusion radius, on the extruded aluminum quality using FEM Simulation Technique. For this purpose, the general FEA Software ABAQUS was used to set up the finite element model of the warm aluminum extrusion in two dimensions (2D). Aluminum alloy Al-2014 wa...

the main objective of an extrusion die is flow balancing as an unbalanced flow causes a distorted product together with residual stress. in this paper a strategy is presented for flow balancing a u-shaped profile with different wall thicknesses. for this purpose, a choker bar is provided at thicker wall to locally restrict excessive flow passing through the thicker section. for optimal design s...

Twist extrusion process is a rather new route to produce highly strained materials. In this process, severe plastic deformation is applied by large shear strains. In current article, required energy for twist extrusion by use of admissible velocity field together with the upper bound technique is predicted. The proposed model is capable of considering the effect of various parameters such as di...

Abstract: In this paper, the forming process of a central hub by radial-forward extrusion is analyzed by using the finite element software, ABAQUS. Radial-forward extrusion is used to produce hollow parts that generally feature a central hub with radial protrusions. Effective design factors such as mandrel diameter, die corner radius, die fillet radius, mandrel corner radius, tube wall thick...

The extrusion of section from round billet poses a great challenge for theoretical modeling of the process using upper bound method. The greatest difficulty in three-dimensional upper bound method is to determine kinematically admissible velocity field. The SERR (Spatial Elementary Rigid Region) technique is fairly applicable for analyzing extrusion of sections having re-entrant corners. A modi...

Mechanical properties response of extruded 6063 aluminum alloy at varied die entry angle has been investigated. Plain carbon and tool steel dies with entry angles of 15, 30, 45, 60, 75 and 90 were simulated. Extrusion on the alloy was done at ambient temperature (37C) and the extruded samples from the various angles were subjected to selected service related mechanical tests and microstructural...