Simulation Study on Influence of Forming Process Parameters on Backward Extrusion Height of 6061 Aluminum-Alloy Wheel

2011 ◽  
Vol 121-126 ◽  
pp. 363-366
Author(s):  
Lu Li ◽  
Fang Wang
Keyword(s):  
Aluminum Alloy ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Forming Process ◽  
6061 Aluminum Alloy ◽  
Backward Extrusion ◽  
Punch Speed ◽  
Alloy Wheel ◽  
Forming Temperature ◽  
Extrusion Technology

Backward extrusion process of aluminum-alloy wheel forging is analyzed by the finite element method. The influence of punch speed and forming temperature on the backward extrusion height of 6061 aluminum alloy wheel is discussed. Studies show that the backward extrusion height increases with increasing forming temperature, and with decreasing punch speed at the same deformation load. It is indicated that when the ranges of forming temperature is from 450 to 500°C and the punch speed is 0.5-1 mm/s, the aluminum alloy wheel has the optimal forming quality. The analysis and conclusions in this paper are helpful in developing the hot extrusion technology specification of 6061 aluminum alloy.

Influences of electric-hydraulic chattering on backward extrusion process of 6061 aluminum alloy

2015 ◽  
Vol 25 (9) ◽  
pp. 3056-3063 ◽  
Author(s):  
Xin-hua HU ◽  
Zhi-heng WANG ◽  
Guan-jun BAO ◽  
Xiao-xiao HONG ◽  
Jun-yi XUE ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Extrusion Process ◽  
6061 Aluminum Alloy ◽  
Backward Extrusion

Recycling of 6061 Aluminum Alloy Cutting Chips Using Hot Extrusion and Hot Rolling

2007 ◽  
pp. 443-446
Author(s):  
Kazutaka Suzuki ◽  
Xin Sheng Huang ◽  
Akira Watazu ◽  
Ichinori Shigematsu ◽  
Naobumi Saito
Keyword(s):  
Aluminum Alloy ◽  
Hot Rolling ◽  
Hot Extrusion ◽  
6061 Aluminum Alloy

Effect of Punch Surface Topography on Friction in Micro Combined Forward and Backward Extrusion of Brass

2014 ◽  
Vol 939 ◽  
pp. 239-244 ◽  
Author(s):  
Chao Cheng Chang ◽  
Cheng Ping Siao
Keyword(s):  
Surface Topography ◽  
Metal Forming ◽  
Electrical Discharge Machining ◽  
Extrusion Process ◽  
Machining Processes ◽  
Forming Process ◽  
Factors Affecting ◽  
Backward Extrusion ◽  
Micro Electrical Discharge Machining ◽  
Metal Forming Process

Friction is one of the key factors affecting the metal forming process. If the friction effects of the process can be accurately modeled, it is able to improve simulations and help the research and development of the metal forming process. This study used cylindrical brass (JIS C2600) billets with the height and diameter of 1.1 mm for conducting the experiments of the micro combined forward and backward extrusion. The purpose of the study was to investigate the effects of punch surface topography on friction in the process. Four surface topography conditions for 0.8 mm diameter punches were prepared by grinding, polishing, grooving and micro electrical discharge machining processes. By comparing the ratio of the cup height to rod length of the extruded cups with the calibration curves established by simulations, the friction factor was estimated in a range from 0.3 to 0.6. The results showed that the punch surface topography significantly affect the friction in the extrusion process. The predicted loads using the estimated friction factors were in good agreement with the experimental results.

Experimental Study of Hot Extrusion Micro Gear of Brass H62

2011 ◽  
Vol 189-193 ◽  
pp. 2903-2906
Author(s):  
Xu Dong Zhou ◽  
Xiang Ru Liu
Keyword(s):  
Dimensional Accuracy ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Plastic Behavior ◽  
Die Materials ◽  
Super Plastic ◽  
3D Fea ◽  
Die Set ◽  
Fea Simulation ◽  
Extrusion Technology

A new micro-forming method, combining a metal’s super-plastic behavior with hot extrudsion technology, has been developed for manufacturing micro-gear from brass H62. The micro-gear, which modulus m = 0.125mm, pressure angle α = 20°, number of teeth z = 6, tip diameter d = 1mm, was selected and its dies were designed with a better die approach angle based on the DEFORM-3D FEA simulation results of the hot extrusion process. Finally the micro-gear was successfully hot extruded at 650°C from blank Φ3mm×3mm with extrusion ratio about 17. A good dimensional accuracy for micro-gear was obtained by using this hot extrusion technology. In the special die set, the split die structure was designed, and the special die materials were chosen, such as the pressure ram was made of tungsten carbide, and the other dies were made of mold materials 4Cr5MoSiV1.

Numerical Simulation of the Stamping Forming Process of Alloy Automobile Panel

2011 ◽  
Vol 704-705 ◽  
pp. 1473-1479
Author(s):  
Jian Zhang ◽  
Yu Lin Ning ◽  
Ben Dong Peng ◽  
Zhi Hua Wang ◽  
Da Sen Bi
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Alloy Sheet ◽  
Forming Process ◽  
Paper Properties ◽  
6061 Aluminum Alloy ◽  
Finite Element Software ◽  
Machine Performance ◽  
Automobile Panel ◽  
Auto Panel

6xxx based alloy auto body sheet will be used widely in the future, but, in the recent, one of the difficulty in practice is its poor formability. In this paper properties parameters of 6061 aluminum alloy sheet are investigated by means of examination; By using machine performance parameters of 6061 aluminum alloy, finite element software eta/DYNAFORM of Sheet Forming make the numerical simulation of auto deck lid outer panel .Stress, plastic strain, thick variety are analyzed; and the wrinkling and cracking prone areas identified. Therefore, the effective reference can be provided for design of forming process of 6xxx Based Alloy auto panel.

Numerical and Experimental Studies on Extrusion of Fan-Shaped Shell of Magnesium Alloy

2012 ◽  
Vol 626 ◽  
pp. 381-385
Author(s):  
Bao Hong Zhang ◽  
Yao Jin Wu ◽  
Zhi Min Zhang
Keyword(s):  
Numerical Simulation ◽  
Magnesium Alloy ◽  
Experimental Studies ◽  
Extrusion Process ◽  
Base Thickness ◽  
Forming Process ◽  
Backward Extrusion ◽  
Minimal Base ◽  
Billet Shape

This paper presents a case study of optimizing the forming process for a fan-shaped shell component. Numerical simulation was used to study the backward extrusion process of a fan-shaped shell. The underfill defect produced at the opening of the extruded shell due to the billet shape was solved and the minimal base thickness required to avoid the presence of the underfill defect at the bottom corner of the component was defined through the numerical simulation. The extrusion drawing and forming process of the fan-shaped shell were designed on the basis of the results of the numerical simulation. Forming experiments had been performed on the fan-shaped shell at 380 °C and cracking was found on the outside wall in the center of the extruded shell. Choked groove on the inner wall of the die and reducing the lubrication had been used to avoid the presence of cracking. The fan-shaped shell of AZ31 magnesium alloy has been successfully formed by the three-stage forming process of hot upsetting, hot backward extrusion and cold sizing.

scholarly journals Influence of the temperature on AA6061 aluminum alloy in a hot extrusion process

2017 ◽  
Vol 13 ◽  
pp. 327-334 ◽  
Author(s):  
M.M. Marín ◽  
A.M. Camacho ◽  
J.A. Pérez
Keyword(s):  
Aluminum Alloy ◽  
Hot Extrusion ◽  
Extrusion Process

A Novel Forming Process for Powder Metallurgy of Superalloys

2014 ◽  
Vol 622-623 ◽  
pp. 833-839 ◽  
Author(s):  
Qian Bai ◽  
Jian Guo Lin ◽  
Gao Feng Tian ◽  
Daniel S. Balint ◽  
Jin Wen Zou
Keyword(s):  
Powder Metallurgy ◽  
Relative Density ◽  
High Performance ◽  
Low Cost ◽  
Hot Isostatic Pressing ◽  
Hot Extrusion ◽  
Forming Process ◽  
Isostatic Pressing ◽  
Wide Range ◽  
Forming Temperature

Powder metallurgy (PM) of nickel-based superalloys has been used for a wide range of products owing to their excellent special properties in processing and applications. Typical processes for high performance PM superalloys include hot isostatic pressing, hot extrusion and hot isothermal forging. Hot isostatic pressing is normally conducted at a high temperature, by using a low pressure for a long time in a closed vessel, resulting in high cost and low product efficiency. In this paper a novel forming process, i.e. direct powder forging for powder metallurgy of superalloys has been proposed. In this process, the encapsulated and vacuumed powder is heated up to the forming temperature and forged directly to the final shape, by using a high forming load for a very short time. Direct powder forging is a low-cost and energy-saving process compared to conventional PM processes, and in addition, press machines of conventional forging can be used for direct powder forming process. In direct powder forging it is important to control the relative density of the deformed part since the existence of voids could reduce the mechanical strength and fatigue life. In this paper, feasibility tests of direct powder forging are presented. Microstructure, relative density and hardness of the formed specimen were studied.

Numerical Simulation of Cold Extrusion Process of the ZA Alloy Car Sleeve Based on LS-DYNA

2013 ◽  
Vol 411-414 ◽  
pp. 3056-3059
Author(s):  
Zhi Qiang Li ◽  
Han Xun Lv ◽  
Bing Dong Liu ◽  
Zhang Yi Yu
Keyword(s):  
Equivalent Stress ◽  
Equivalent Plastic Strain ◽  
Processing Parameters ◽  
Extrusion Process ◽  
Raw Material ◽  
Cold Extrusion ◽  
Forming Process ◽  
Contrastive Study ◽  
Finite Element Technology ◽  
Extrusion Technology

In order to increase the useful life of sleeve, improve the organizational structure and reduce costs, ZA alloy materials can be used as a raw material using cold extrusion technology for production. The main content of this paper is simulating the change rules of the equivalent plastic strain, the equivalent stress and the flow in the forming process of ZA alloy in different extrusion speed and friction coefficient condition by finite element technology, making a contrastive study with the extrusion theory, and finding out the most appropriate extrusion processing parameters. The results not only provide sufficient theatrical support for the cold extrusion process of sleeve of ZA alloy, but also offer some new thoughts for the design of extrusion mold.

Numerical and Experimental Investigation on Hot Backward Extrusion Process of Mg-Gd-Y-Zn-Zr Magnesium Alloy

2014 ◽  
Vol 788 ◽  
pp. 127-133 ◽  
Author(s):  
Zhi Wen Shao ◽  
Xiu Rong Zhu ◽  
Jun Wang ◽  
Rong Wang ◽  
Yong Dong Xu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Magnesium Alloy ◽  
Hot Extrusion ◽  
Element Model ◽  
Extrusion Process ◽  
Tensile Yield Strength ◽  
Secondary Phases ◽  
Rigid Plastic ◽  
Backward Extrusion ◽  
The Matrix

The hot backward extrusion process of the Mg-Gd-Y-Zn-Zr magnesium alloy was investigated by both numerical simulation and experiments. An axisymmetric 2D rigid-plastic finite element model (FEM) was established to simulate the material flow during the extrusion process. The shapes of the dies were optimized in order to avoid severe stress concentration and obtain uniform deformation of the workpiece. After hot extrusion, the microstructures of the alloys were obviously refined, and the secondary phases which included many long-period stacking order (LPSO) phases precipitated in the matrix. The optimal comprehensive mechanical properties of the alloy have been obtained after extrusion and ageing at 200°C for 48h with the ultimate tensile strength of 434MPa, tensile yield strength of 375MPa and elongation of 4.5%, respectively. The good mechanical properties were mainly attributed to the fine microstructures and numerous precipitates in the matrix.

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