Numerical Simulation of Tube Extrusion Process of AISI304 and Comparing with Upper Bound Solutions

Document Type : Original Articles

Authors

Malek-e Ashtar University of Technology

Abstract

The study purpose was to evaluate the effect of initial billet temperature, extrusion speed, extrusion ratio and angle on the tube extrusion process of AISI304, particularly the extrusion force, and achieve optimal parameters. Abaqus software was used for the simulation purpose. 12 samples were evaluated with different initial conditions. Two-dimensional axisymmetric model was used to simulate the process, due to the axial symmetry of the process. Mechanical-thermal coupled solution was used for process solution. Also, CAX4RT elements were used for achieving all the degrees of freedom. The initial temperature was found to have the strongest effect on the force.

Keywords


  1. Li L., Zhang H., Zhou J., Duszczyk J., Li G.Y., Zhong Z.H., "Numerical and Experimental Study on the Extrusion through a Porthole Die to Produce a Hollow Magnesium Profile with Longitudinal Weld Seams", Materials and Design, Vol. 29, pp. 1190-11098, (2008).
  2. Guo L.G., Dong K.K., Zhang B.J., Yang H., Zheng W.D., Liu X.W., “Dynamic Recrystallization Rules in Needle Piercing Extrusion for AISI304 Stainless Steel Pipe”, Transaction of Nonferrus Metals Society of China, Vol. 22, pp. 519-527, (2012).
  3. Sofuoglu H., Gedikli H., “Physical and Numerical Analysis of Three Dimensional Extrusion Process”, Computational Materials Science, Vol. 31, pp. 113-124, (2004).
  4. Kobayashi S., Oh S., Altan T., “Metal Forming and the Finite-Element Method”, Oxford University Press, (1989).
  5. Fietier N., Krahenbuhl Y., Vialard M., “New methods for the fast simulations of the extrusion process of hot metals”, Journal of Materials Processing Technology, Vol. 209, pp. 2244-2259, (2009).
  6. Hansson S., Jansson T., “Sensitivity Analysis of a Finite Element Model for the Simulation of Stainless Steel Tube Extrusion”, Journal of Materials Processing Technology, Vol. 210, pp. 1386-1396, (2010).
  7. Damodaran D., Shivpuri R., “Prediction and Control of Part Distortion during the Hot Extrusion of Titanium Alloys”, Journal of Materials Processing Technology, Vol. 150, pp. 70-75, (2004).
  8. Li L.X., Rao K.P., Lou Y., Peng D.S., “A Study on Hot Extrusion of Ti-6Al-4V Using Simulations and Experiments”, International Journal of Mechanical Sciences, Vol. 44, pp. 2415-2425, (2002).
  9. Hansson S., “Modeling of the Stainless Steel Tube Extrusion Process”, DOC, Department of Applied Physics and Mechanical Engineering, Lulea University of technology, (2009).
  10. Epler M.E., Misiolek W.Z., “Novel Billet Design for Co-extrusion of Ferrous Material Tubes”, Materials Science and Engineering, Vol. 429, pp. 43-50, (2006).
  11. Sivaprasad P.V., Venugopal S., Davies C.H.J., Prasad Y.V., “Indentification of Optimum Process Parameters for Hot Extrusion Using Finite Element Simulation and Processing and Processing Maps”, Modelling and Simulation in Materials Science, Vol. 12, pp. 285-291, (2004).
  12. Czarkowski P., Krawczynska A.T., Slesinski R., Brynk T., Budniak J., Lewandowska M., Kurzydlowski K.J., “Low Temperature Mechanical Properties of 316L Type Stainless Steel after Hydrostatic Extrusion”, Fusion Engineering and Design, Vol. 86, pp. 2517-2521, (2011).
  13. Alfaro I., Bel D., Cueto E., Doblare M., Chinesta F., “Three-dimensional simulation of aluminium extrusion by the α-shape based natural element method”, Computer Methods in Applied Mechanics and Engineering, Vol. 195, pp. 4269-4286, (2006).
  14. Hansson S., Fisk M., “Simulations and Measurements of Combined Induction Heating and Extrusion Processes”, Finite Elements in Analysis and Design, Vol. 46, pp. 905-915, (2010).
  15. Gouveria B.P.P.A., Rodrigues J.M.C., Martins P.A.F., Bay N., “Physical Modeling and Numerical Simulation of the round-to-square Forward Extrusion”, Journal of Materials Processing Technology, Vol. 112, pp. 244-251, (2001).
  16. Paine A., Aloe M., Walters J., “Simulation of Hot Extrusion Processes”, Aluminum Extrusion, Vol. 7, pp. 39-44, (2002).
  17. Lenard J.G., Pietrzyk M., Cser L., “Mathematical and physical simulation of the properties of hot rolled”, Elsevier, Tokyo, (1999).
  18. Hansson S., “Modeling of the Stainless Steel Tube Extrusion Process”, DOC, Department of Applied Physics and Mechanical Engineering, Lulea University of technology, (2009).
  19. Haghighat H., Moradmand M., “Upper Bound Analysis of Thick Wall Tubes Extrusion Process Through Rotating Curved Dies”, Mechanica, Vol. 48, pp. 1947-1958, (2013).
  20. Chang K.T., Choi J.C., “Upper-Bound Solutions to Tube Extrusion Problems Through Curved Dies”, Journal of Engineering for Industry, pp. 1108-1111, (1972).
  21. Park S.S., You B.S., Yoon D.J., Effect of the Extrusion Conditions on the Texture and Mechanical Properties of Indirect-Extruded Mg–3Al–1Zn Alloy”, Journal of Materials Processing Technology, Vol. 209, pp. 5940-5943, (2009).
  22. Ebrahimi R., Reihanian M., Kanaani M., Moshksar M.M., “An Upper-Bound Analysis of the Tube Extrusion Process”, Journal of Materials Processing Technology, Vol. 199, pp. 214-220, (2008).
  23. Hoffmanner A.L., ”Metal Forming Interrelation between Theory and Practice”, Plenum Press, New York, (1971).
  24. Bosetti P., Maximiliano C., Bort G., Bruschi S., “Identification of Johnson–Cook and Tresca’s Parameters for Numerical Modeling of AISI-304 Machining Processes”, Journal of Manufacturing Science and Engineering, Vol. 135, pp. 1-8, (2013).
  25. Li L., Zhou J., Duszczyk J., “Determination of a Constitutive Relationship for AZ31B Magnesium Alloy and Validation Through Comparison between Simulated and Real Extrusion”, Journal of Materials Processing Technology, Vol. 172, pp. 372-380, (2006).
  26. Yang L., Geng Z., Zhang M., Dong J., “Study on Hot Deformation Behavior and Numerical Simulation for Hot Extrusion Process of Corrosion Resistant 825 Alloy”, Procedia Engineering, Vol. 27, pp. 997-1007, (2012).
  27. Roberts G., Krauss G., Kennedy R., “Tool Steels”, 5th Edition, ASM International, USA, (1998).
CAPTCHA Image