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.

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.

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.

FVM Simulation of Porthole Die Extrusion Process for a Large Caliber Aluminum Tube Profile

2015 ◽  
Vol 778 ◽  
pp. 116-119
Author(s):  
Rui Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Finite Volume Method ◽  
Finite Volume ◽  
Extrusion Process ◽  
Aluminum Tube ◽  
Porthole Die ◽  
Aluminum Profile ◽  
Volume Method ◽  
Aluminum Profile Extrusion

Aiming at the aluminum profile extrusion process of a large caliber aluminum tube with porthole die, this paper established the simulation models by using finite element method and finite volume method, respectively. The extrusion process was simulated by using the above two models. The advantages and disadvantages and the applicability of the two simulation methods in simulating large aluminum profile extrusion processes were compared. It is concluded that finite volume method is more suitable than finite element method for simulating aluminum profile extrusion processes with a severe deformation. In addition, the distributions of stress and strain and the material flow patterns in the large caliber aluminum tube extrusion process with porthole die were given in detail. The results can provide useful theoretical guidelines for the process and die design as well as process parameter optimal selection for large aluminum profile extrusion processes with porthole die.

Study on the Intelligent Design System of Square Tube Aluminum Profile Extrusion Processes Based on VB

2012 ◽  
Vol 549 ◽  
pp. 884-888
Author(s):  
Zhi Ping Zhang ◽  
Han Wu Liu ◽  
Xiao Xia Li
Keyword(s):  
Programming Language ◽  
Intelligent Design ◽  
Extrusion Process ◽  
Design System ◽  
Aluminum Extrusion ◽  
Forming Process ◽  
Extrusion Die ◽  
Aluminum Profile ◽  
Extrusion Forming ◽  
Aluminum Profile Extrusion

According to the similar characteristics of structure, geometry and constraints conditions in the same type of extrusion process, the intelligent design system of a square tube aluminum profile extrusion forming process was established in this paper based on the VB programming language, with using parametric programming language APDL provides by ANSYS software. The parameterized optimization design plan of pre-treatment and post-processing of ANSYS analysis during a square tube aluminum extrusion forming process was achieved, and the program of a three-dimensional model of the extrusion die under Visual Lisp environment was also programmed. The human-computer interaction intelligent design system which combined with pre-processing of semi-finished product, finite element analysis of extrusion die strength, extrusion die temperature field analysis, structural optimization of the die was realized. The research results show that the system can provide program decision-making, structural design, performance analysis and graphics treatment for the actual extrusion productions of square tube aluminum extrusion process, which reduced the design time of the technical staff, and saved design cost.

Finite Volume Simulation and Multi Parameters Optimization on Extrusion of Complex Aluminum Profile

2010 ◽  
Vol 97-101 ◽  
pp. 395-399
Author(s):  
Ze Zhong Chen ◽  
Zhong Xu Bao
Keyword(s):  
Finite Volume ◽  
Extrusion Process ◽  
Friction Model ◽  
Parameters Optimization ◽  
Complex Aluminum ◽  
Aluminum Profile ◽  
Artificial Neural Network Ann ◽  
Finite Volume Simulation ◽  
Volume Method ◽  
Aluminum Profile Extrusion

In this paper, finite volume method (FVM) is adopted to simulate complex irregular aluminum profile extrusion process. The basic theory of FVM, the materials model, friction model, and a computer aided optimization (CAO) model based on orthographic experiments, artificial neural network (ANN) and genetic algorithm (GA) are presented. A complex aluminum profile extrusion is simulated and optimized. The results show FVM simulation is a good way for the description of material flow, and mesh distortion could be avoided effectively. Optimal values of multi parameters are also obtained. Experiment shows good fit among the simulation, optimization and the experimental results.

Prediction of Three-Dimensional Steady Incompressible Flows Using Body-Fitted Coordinates

1993 ◽  
Vol 115 (3) ◽  
pp. 457-462 ◽  
Author(s):  
P. Tamamidis ◽  
D. N. Assanis
Keyword(s):  
Cross Section ◽  
Incompressible Flows ◽  
Three Dimensional ◽  
Computational Time ◽  
Complex Geometries ◽  
Curved Duct ◽  
Sensitivity Studies ◽  
Simplec Algorithm ◽  
Volume Method ◽  
Strong Curvature

A finite-volume method for three-dimensional, steady, incompressible flows in complex geometries is presented. The method uses generalized Body-Fitted Coordinates to accurately take into account the shape of the boundary. A collocated scheme is employed, which uses the three covariant velocities and the pressure as main variables. Continuity is coupled with the momentum equations using the SIMPLEC algorithm. It is found that the SIMPLEC algorithm can provide savings in computational time of up to 40 percent compared to calculations with SIMPLE. Sensitivity studies are also performed to find optimum values of the underrelaxation parameters. The method is validated against experimental results for the case of the flow in a 90 deg curved duct of square cross-section and comparatively strong curvature. The application of the method to the prediction of flows in complex geometries is then illustrated.

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.

Simulation on Multi-Oil-Cavity and Multi-Oil-Pad Hydrostatic Bearings

2013 ◽  
Vol 274 ◽  
pp. 274-277 ◽  
Author(s):  
Xiao Qiu Xu ◽  
Jun Peng Shao ◽  
Xiao Dong Yang ◽  
Yan Qin Zhang ◽  
Xiao Dong Yu ◽  
...  
Keyword(s):  
Hydraulic System ◽  
Thrust Bearing ◽  
Three Dimensional ◽  
Structure Design ◽  
Analysis Software ◽  
Hydrostatic Bearing ◽  
Hydrostatic Bearings ◽  
Simulation Results ◽  
Three Dimensional Models ◽  
Volume Method

Taking multi-oil-cavity and multi-oil-pad hydrostatic bearings as studied projects, firstly make brief instructions for structure characteristics and working principal of hydraulic system; Then, build three-dimensional models of multi-oil-cavity and multi-oil-pad hydrostatic bearings respectively. Adopting finite volume method, oil film mesh is generated by universal finite analysis software CFD; then, carry on numerical simulations for pressure distribution and temperature distribution of the two studied hydrostatic thrust bearing under various viscosity, and make comparative analysis for difference between the two studied hydrostatic thrust bearing. Based on the analysis of numerical simulation results, the conclusions whether oil-return groove is set for hydrostatic bearing could be received. Simulation results reveal truly the influence of setting oil-return groove or not on hydrostatic thrust bearing, and improve structure design for hydrostatic thrust bearing.

Study on Precision Forging Schemes of Hypoid Driving Gear

2012 ◽  
Vol 472-475 ◽  
pp. 692-695
Author(s):  
Jian Hua Wang ◽  
Fu Xiao Chen
Keyword(s):  
Equivalent Stress ◽  
Three Dimensional ◽  
Equivalent Strain ◽  
Precision Forging ◽  
Forming Technology ◽  
Blank Shape ◽  
Simulation Results ◽  
Three Dimensional Models ◽  
3D Software ◽  
Deform 3D

By analyzing the characteristics and forming technology of hypoid driving gear, it was suitable for adopting fully enclosed die forging principle to form the gear. Based on different forging methods, three kinds of blank shape and corresponding forming schemes were designed. The three dimensional models of blank and die were created by the UG software. The three forming schemes were simulated by the Deform-3D software. The simulation results of distribution of equivalent stress, distribution of equivalent strain and load-stroke curve were comparatively analyzed. Then the most reasonable scheme was chosen. At last, the rationality of numerical simulation can be further verified by the optimized scheme was proved by experiment.

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