Modeling of Aluminum Extrusion Process Using Non-Orthogonal Block Structured Grids Based FVM

2011 ◽  
Vol 189-193 ◽  
pp. 1749-1752
Author(s):  
Rui Wang ◽  
Hong Zhong Li
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Special Treatment ◽  
Aluminum Extrusion ◽  
Rigid Plastic ◽  
Structured Grids ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Die Extrusion

The mathematic model of 3D aluminum extrusion processes using finite volume method (FVM) was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Non-orthogonal structured grids were used to match complex geometric boundaries and local refinement of grids was also realized. The collocated arrangement is used to discretize the governing equations on non-orthogonal grids directly, pressure oscillations bring by this arrangement and error caused by grid’s non-orthogonality is eliminated by special treatment. A pocket die extrusion process was simulated using the program developed in this paper. The simulation results were also compared with that simulated by FEM software Deform in the same process, material and die conditions. The feasibility and efficiency of the mathematic model built in this paper was demonstrated by the simulation results and the comparison.

Body Fitted Grids Based FVM Simulation of Aluminum Extrusion Process

2011 ◽  
Vol 418-420 ◽  
pp. 2102-2105
Author(s):  
Rui Wang
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Friction Model ◽  
Aluminum Extrusion ◽  
Local Refinement ◽  
Rigid Plastic ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Process Material

A body fitted based finite volume method (FVM) model of aluminum extrusion processes was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Body fitted grids were used to match complex geometric boundaries and local refinement of grids was also realized. Plastic shear friction model was applied on body fitted grids. A typical then walled profile extrusion process was simulated using the program developed in this paper. The simulation results were also compared with that simulated by FEM software Deform in the same process, material and die conditions. The feasibility and efficiency of the mathematic model built in this paper was demonstrated by the simulation results and the comparison.

FVM Simulation of Large Deformational Aluminum Extrusion Process and Die Bearing Optimization

2010 ◽  
Vol 97-101 ◽  
pp. 400-403
Author(s):  
Rui Wang
Keyword(s):  
Three Dimensional ◽  
Mathematic Model ◽  
Extrusion Process ◽  
Complex Geometries ◽  
Aluminum Extrusion ◽  
Aluminum Profile ◽  
Simulation Results ◽  
Volume Method ◽  
Aluminum Profile Extrusion ◽  
Deform 3D

The mathematic model of three-dimensional aluminum profile extrusion processes using finite volume method (FVM) was established in this paper. Basic theory and key technologies of this model were researched and built. Non-orthogonal blocked structured girds were used to fit complex geometries. Volume of Fluid (VOF) scheme was used to capture the free surface of the deforming materials. A program AE-FVM was written according to the above theories and equations. A thin walled aluminum profile extrusion process was simulated and optimized using AE-FVM. The simulation results were also compared with that simulated by Deform-3D and SuperForge in the same conditions. The feasibility of the mathematic model built in this paper was demonstrated by the simulation results comparison.

Numerical Simulation of Aluminum Extrusion Process Using Body-Fitted Grids Based Finite Volume Method

2014 ◽  
Vol 602-605 ◽  
pp. 64-68
Author(s):  
Yu Jie Zhang ◽  
Xiao Feng Gong ◽  
Rui Wang ◽  
Xiao Qing Feng
Keyword(s):  
Finite Volume Method ◽  
Finite Volume ◽  
Initial Conditions ◽  
Effective Strain ◽  
Mathematic Model ◽  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Computational Region ◽  
Coordinate Conversion ◽  
Volume Method

A mathematic model of aluminum extrusion process using body-fitted grids based finite volume method was studied and established in this paper. The basic goverment equations of the finite volume method were built, body-fitted grids were used to mesh computational region, basic goverment equations were discretized on body fitted grids directly, so complex coordinate conversion was avoided by no use of aptamer coordinate system. Initial conditions, boundary conditions and calculation processes of aluminum extrusion process finite volume method were studied and established, a program had been written based this model and a typical process of aluminum extrusion was simulated, amount of physical fields such as velocities, effective stress and effective strain rate etc. were obtained, the results were compared with that simulated by finite element method, so the feasibility and exactness of the mathematic model is proved.

Aluminum Rod Extrusion and Material Modeling

2008 ◽  
Vol 367 ◽  
pp. 71-78
Author(s):  
P.T. Moe ◽  
Yawar Abbas Khan ◽  
Henry Sigvart Valberg ◽  
Sigurd Støren
Keyword(s):  
Temperature Measurement ◽  
Constitutive Relations ◽  
Simulated Data ◽  
Thermal Conditions ◽  
Extrusion Process ◽  
Material Modeling ◽  
Outlet Temperature ◽  
Aluminum Extrusion ◽  
Scientific Approach ◽  
Simulation Results

The article presents an outline of a scientific approach for testing constitutive relations for the aluminum extrusion process. By comparing ram force, container friction, die face pressure, outlet temperature measurement during rod extrusion with corresponding simulated data, inferences can in principle be drawn with respect to the validity models. The paper indicates that simulation results from the 2D ALMA2π program are in fair agreement with measurements during extrusion of AA6060, but more work needs to be done to control thermal conditions during extrusion.

CFD Investigation of Performance for Marine Current Turbine Based on RANS Simulations

2009 ◽  
Vol 419-420 ◽  
pp. 309-312 ◽  
Author(s):  
Rui Jun Fan ◽  
J.R. Chaplin ◽  
Guang Jun Yang
Keyword(s):  
Pitch Angle ◽  
Compressible Flows ◽  
Structured Grids ◽  
Numerical Predictions ◽  
Marine Current Turbine ◽  
Marine Current ◽  
Simulation Results ◽  
Volume Method ◽  
Current Turbine ◽  
Blade Pitch Angle

This paper presents the 3D CFD computation of an 800mm diameter model of MCT based on structured grids, RANS equations and turbulence model. A time-accurate, upwind, finite volume method for computing compressible flows on structured grids is presented. Numerical predictions for a series of blade pitch angle settings and speeds are compared with the other simulation results of commercial software, verified by the experimental measurement of the model. Such results provide confidence in using the CFD computation tools to develop the forthcoming design of MCT.

Studies on Process Parameters for Aluminum Extrusion of Slide Rails

2013 ◽  
Vol 467 ◽  
pp. 392-397 ◽  
Author(s):  
Shun Yu Shao ◽  
Wen Yen Wang ◽  
Yi An Chen
Keyword(s):  
Aluminum Alloy ◽  
Process Design ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Roll Forming ◽  
Aluminum Extrusion ◽  
Extrusion Speed ◽  
Extrusion Die ◽  
Simulation Results ◽  
Product Weight

Slide rails are usually fabricated by roll forming and are used in kitchenware and cabinets mostly. However the product weight of slide rails is increased because larger dimensions are required to bear larger load when they are used in dies and warehouses. International suppliers start to develop Aluminum slide rails to decrease the product weight in recent years. The manufacturing and functional feasibility of Aluminum slide rail were discussed in this study. The Aluminum slide rail was designed according to ready-made slide rail, and the aluminum alloy was selected with required mechanical properties. The suitable extrusion die was designed and direct extrusion parameters of extrusion ratio, extrusion temperature, extrusion speed and extrusion load are also considered. The extrusion process of aluminum alloy was simulated by CAE software to check the mold and process design. The extrusion part of aluminum slide rail was carried out by extruder to verify the simulation results.

An Analysis on the Surface Expansion of Aluminium Alloys in Backward Can Extrusion Process

2006 ◽  
Vol 519-521 ◽  
pp. 931-936 ◽  
Author(s):  
J.H. Ok ◽  
Beong Bok Hwang
Keyword(s):  
Aluminum Alloys ◽  
Material Flow ◽  
Extrusion Process ◽  
Process Conditions ◽  
Geometrical Parameters ◽  
Rigid Plastic ◽  
Geometrical Condition ◽  
Aa 2024 ◽  
Surface Expansion ◽  
Simulation Results

This paper is concerned with the analysis on the surface expansion of AA 2024 and AA 1100 aluminum alloys in backward extrusion process. Due to heavy surface expansion appeared usually in the backward can extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the surface expansion is analyzed especially under various process conditions. The main goal of this study is to investigate the influence of degree of reduction in height, geometries of punch nose, friction and hardening characteristics of different aluminum alloys on the material flow and thus on the surface expansion on the working material. Two different materials are selected for investigation as model materials and they are AA 2024 and AA 1100 aluminum alloys. The geometrical parameters employed in analysis include punch corner radius and punch face angle. The geometry of punch follows basically the recommendation of ICFG and some variations of punch geometry are adopted to obtain quantitative information on the effect of geometrical parameters on material flow. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward can extrusion process under different geometrical, material, and interface conditions. The simulation results are summarized in terms of surface expansion at different reduction in height, deformation patterns including pressure distributions along the interface between workpiece and punch, comparison of surface expansion between two model materials, geometrical and interfacial parametric effects on surface expansion, and load-stroke relationships. It has been concluded from the present study that the geometrical condition of punch is the most significant factor among the parameters employed in this study. It is also known from the simulation results that the difference in surface expansion according to different material properties is not more or less significant.

Numerical Simulation of Extrusion Process to Produce Complex Aluminum Profiles Using the ALE Approach

2014 ◽  
Vol 1004-1005 ◽  
pp. 1260-1264
Author(s):  
Lei Cheng ◽  
Guo Jie Huang ◽  
Jian Wei Wang ◽  
Wei Xiao ◽  
Shui Sheng Xie
Keyword(s):  
Numerical Simulation ◽  
Extrusion Process ◽  
Die Design ◽  
Optimized Design ◽  
Aluminum Extrusion ◽  
Arbitrary Lagrangian Eulerian ◽  
Simulation Technology ◽  
The Individual ◽  
Volume Method ◽  
Aluminum Profiles

Although still having certain limitations, the numerical simulation technology has been increasingly applied to aid in optimizing the aluminum extrusion process and die design. In the present research, numerical simulations of the profiles extrusion process were performed, using the Finite Volume Method (FVM) and Finite Element Method (FEM) to make use of the individual merits of the Euler approach and Lagrange approach, respectively. The application of the simulation technology to produce large, complex profiles has, however, been quite limited. In order to solve the limited, numerical simulation of aluminum profiles with large and complicated cross-section in extrusion process was achieved using Arbitrary Lagrangian-Eulerian (ALE) approach, and non-uniform velocities at the die exit, leading to extrudate distortions, were predicted. Extrusion experiments proved that the die with the optimized design could circumvent the distortion problem. The numerical simulation technology can indeed be effectively used to reduce the number of die trials and offer the potential to realize zero die trial.

Sign in / Sign up

Export Citation Format

Share Document