3D FEM Geometry and Material Flow Optimization of Porthole-Die Extrusion

2007 ◽  
Author(s):  
Elisabetta Ceretti ◽  
Luca Mazzoni ◽  
Claudio Giardini
Keyword(s):  
Material Flow ◽  
3D Fem ◽  
Flow Optimization ◽  
Porthole Die ◽  
Die Extrusion ◽  
Porthole Die Extrusion

3D FEM-NEM Material Joining Simulation in Porthole Die Extrusion

2011 ◽  
Vol 491 ◽  
pp. 151-158 ◽  
Author(s):  
Francesco Gagliardi ◽  
I. Alfaro ◽  
Luigino Filice ◽  
E. Cueto
Keyword(s):  
Finite Element ◽  
Complex Geometry ◽  
Experimental Investigations ◽  
3D Analysis ◽  
3D Fem ◽  
Positive Effects ◽  
Tube Extrusion ◽  
Porthole Die ◽  
Die Extrusion ◽  
Porthole Die Extrusion

The conventional tube extrusion process has been substituted by porthole die extrusion due to relevant advantages in terms of productivity and quality. However, the porthole die has a complex geometry to be effectively designed; consequently, several studies can be found out in the technical literature based on experimental and finite element analyses of the process. From this point of view, while the experimental investigations entail cost and time increasing, due to the die building complexity, finite element techniques present some drawbacks such as the difficulty to simulate material joining and the loss of accuracy due to the heavy mesh distortion and related remeshing. Therefore, the introduction of new numerical techniques for the analyses of this process could have positive effects. In this paper, the Natural Element Method (NEM) together to the alpha shapes and some extra numerical procedures are used in the simulation of tube extrusion, focusing the attention on the simulation of the welding line in a fully 3D analysis. The obtained results are compared with the finite element and experimental ones, measuring the accuracy of the proposed methodology.

Experimental and Numerical Analysis of Material Flow in Porthole Die Extrusion

2011 ◽  
Vol 491 ◽  
pp. 97-104 ◽  
Author(s):  
Thomas Kloppenborg ◽  
M. Schwane ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya ◽  
Alexander Brosius
Keyword(s):  
Numerical Analysis ◽  
Material Flow ◽  
Aluminum Extrusion ◽  
Fundamental Knowledge ◽  
Porthole Die ◽  
Accurate Design ◽  
Simulation Results ◽  
Software Codes ◽  
Die Extrusion ◽  
Porthole Die Extrusion

The design of porthole dies for aluminum extrusion processes is very complex. For the accurate design, fundamental knowledge about material flow is of major importance. To gain these information, numerical methods are increasingly utilized. The accuracy of the simulation results depends mainly on the precision of the used boundary conditions in the model. Therefore, visioplastic analyses of the material flow inside a porthole die are presented in this paper. A special modular tool concept was developed to prepare and visualize the material flow inside the process. The results of the experimental analysis were used for the verification of numerical results which were calculated with the commercial software codes Deform3D and HyperXtrude.

FEM simulation of welding quality in porthole die extrusion

2011 ◽  
Vol 26 (2) ◽  
pp. 292-295 ◽  
Author(s):  
Youfeng He ◽  
Shuisheng Xie ◽  
Lei Cheng ◽  
Guojie Huang ◽  
Yao Fu
Keyword(s):  
Fem Simulation ◽  
Welding Quality ◽  
Porthole Die ◽  
Die Extrusion ◽  
Porthole Die Extrusion

Effects of Process Parameters on Charge Weld Length during Multi-Hole Porthole Die Extrusion

2014 ◽  
Vol 703 ◽  
pp. 141-145 ◽  
Author(s):  
Liang Chen ◽  
Guo Qun Zhao ◽  
Ting Ting Wang
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Optimal Process ◽  
Extrusion Speed ◽  
Billet Temperature ◽  
Porthole Die ◽  
Element Simulation ◽  
Die Extrusion ◽  
Charge Weld ◽  
Porthole Die Extrusion

The evolution of charge weld during multi-hole porthole die extrusion was studied by means of finite element simulation and Taguchi’s design. Moreover, based on S/N analysis, the optimal process parameters that can reduce the charge weld length was obtained, where the billet diameter is 100 mm, extrusion speed is 2.0 mm/s, tool temperature is 430 °C and billet temperature is 465 °C. The accuracy and effectiveness of such optimal process parameters were also verified. The purpose of the present study is to provide some information about the controlling of charge weld for extrusion engineers.

Physical Simulation of Longitudinal Welding in Porthole-Die Extrusion

CIRP Annals ◽  
2006 ◽  
Vol 55 (1) ◽  
pp. 287-290 ◽  
Author(s):  
P.F. Bariani ◽  
S. Bruschi ◽  
A. Ghiotti
Keyword(s):  
Physical Simulation ◽  
Porthole Die ◽  
Die Extrusion ◽  
Porthole Die Extrusion

NEM-FEM comparison on porthole die extrusion of AA-6082

2013 ◽  
Vol 27 (4) ◽  
pp. 1089-1095 ◽  
Author(s):  
Francesco Gagliardi ◽  
Iciar Alfaro ◽  
Giuseppina Ambrogio ◽  
Luigino Filice ◽  
Elias Cueto
Keyword(s):  
Porthole Die ◽  
Die Extrusion ◽  
Porthole Die Extrusion

Effects of Multi-Step Welding Chamber on Extrusion Product Quality and Die Strength

2010 ◽  
Vol 44-47 ◽  
pp. 311-315
Author(s):  
Hao Chen ◽  
Guo Qun Zhao ◽  
Cun Sheng Zhang ◽  
Dao Sheng Wen
Keyword(s):  
Product Quality ◽  
Maximum Stress ◽  
Metal Flow ◽  
Extrusion Process ◽  
Porthole Die ◽  
Die Life ◽  
Die Extrusion ◽  
Extrusion Product ◽  
Porthole Die Extrusion ◽  
Key Parameter

The shape of welding chamber is a key parameter in flat porthole die extrusion process, which influences product quality and die life-span directly. In this paper, by means of numerical simulation of the extrusion process for an aluminum hollow profile, the effects of multi-step welding chamber on metal flow and die strength have been investigate. The numerical results revealed that the multi-step welding chamber was effective to balance metal flow in the die cavity. In addition, with an increasing step of welding chamber, the maximum stress and deflection of the lower die decreased, while the deflection of the mandrel kept almost unchanged and the maximum stress of upper die increased.

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