• Journal of the Korean Society for Heat Treatment
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• v.34 no.4
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• pp.185-190
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• 2021

The extrusion experiments using the 7075 aluminum billet have been performed to investigate the effects of die cooling and ram speed on the occurrence of surface defects on the extrudate. The purpose of die cooling was to suppress overheating of the extrudate at the moment of extrusion. In the present die cooling system, liquid nitrogen has been injected in to the die and sprayed to the surface of extrudate. Ram speed was either kept or varied in the range of 1.1~1.7 mm/sec. throughout one extrusion shot to check the occurrence of surface defects. Every extrusion started at a ram speed of 1.25 mm/sec. The temperature of extrudate was measured using a laser thermometer. The 7075 billet of 180 mm in diameter and 550 mm in length was preheated at 390℃ and extruded to get a single plate of 8000 mm in length, 150 mm in width and 10 mm in thickness. Each extrudate was checked by eye to find the surface defects. The microstructures were obtained in the specimen cut from each corner of the extrudate using the EBSD micrographs.

• Journal of the Korean Society for Heat Treatment
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• v.35 no.6
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• pp.319-326
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• 2022

Direct extrusions of an aluminum 7075 alloy were carried out using 1500 ton machine with and without die cooling system. Cooling of extrusion die has been performed by the flow of liquid nitrogen and controlled by laser thermometer. Billet was 180 mm in diameter and 500 mm in length. The preheating temperatures of billet, container and die were 390℃, 400℃ and 450℃, respectively. Ram speed was kept with 1.25 mm/sec first. The change of ram speed was carried out during extrusion according to the observation of surface defects such as crack or tearing. Extrudates of 8.3 m in length, 100 mm in width and 15 mm in thickness were obtained to observe and analyze surface defects by optical microscopy and EBSD (Electron BackScattered Diffraction). In case of extrusion without die cooling cracks on the surface and tearing in the corner of extrudate occurred in the middle stage and developed in size and frequency during the late stage of extrusion. At the extrusion with die cooling the occurrence of defects could be suppressed on the most part of extrudate. EBSD micrographs showed that cracks and tearings have been resulted from the same origin. Surface defects were generated at the boundaries of grains formed by secondary recrystallization due to surface overheating during extrusion.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.210-213
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• 1995

In this study,the effect of both process parameters (wheel velocity, friction coefficients between die and billet, etc) and die-shape (abutment height and shape, flash gap, etc.) on the surface defect on forming process is theoretically investigated. For this work, computer simulation was performed by using the DEFORM, a commercial FEM code. Through numerous simulations with different parameters and die shapes, We propose one optimal die shape for CONFORM process which can remove surface defect.

• Transactions of Materials Processing
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• v.10 no.2
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• pp.111-114
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• 2001

A new, simple method to determine the die shape using a streamline in extrusion is presented. This method assumes that a billet deforms naturally to minimize the energy input for the given process condition. Then, an optimal die shape can be determined along a streamline. Extrusion operations with two types of materials, strain-hardening material and strain-rate hardening material, are examined using this method. Predictions with the proposed method are compared with those by the previous optimizing model to show its efficiency.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.79-82
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• 2000

A new simple method to determined the die shape using a streamline in extrusion is presented. This method assumes that a billet deforms naturally to minimize the energy input for the given process condition. Then an optimal die shape can be determined along a streamline. Extrusion operations with two types of materials strain-hardening material and strain-rate hardening material are examined using this method. Prediction with the proposed method are compared with those by the previous optimizing model to show its efficiency.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1996.05a
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• pp.187-193
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• 1996

항공 우주 재료 중에서 알루미늄 합금 재료가 차지하는 비중은 매우 크다. 사용 조건에 적합한 특성을 갖도록 하기 위한 연구 노력 중의 한 가지가 단조품 조직의 미세화이다. 일반적으로 조직을 미세화 하는 방법으로는 I.T.M.T 공법을 적용하고 있으나, 러시아에서는 미세 균일한 조직의 알루미늄 열간 단조품을 제조하기 위하여 billet의 주조 공정에서 초음파 처리(U.S.T)를 적용하고 열간 단조 공정에서는 조직 상태도를 활용하여 성형 단계별 소성 가공량의 조절과 작업 온도를 관리함으로서 미세 균일 조직의 대형 알루미늄 단조품을 생산하고 있다.

• Journal of the Korea Institute of Military Science and Technology
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• v.6 no.1
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• pp.68-80
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• 2003

The backward extrusion process of titanium alloy with large length to diameter ratio was simulated for different punch and die shape. The process variables such as initial billet shape, interface friction, contacting time and punch velocity were investigated and compared with experimental results. To make more effectively titanium alloy cup shape forging products with vertical wall, a modified die design which can reduce forging load, prevent sticking with punch and minimize material loss was suggested.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.11
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• pp.1361-1370
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• 2012

A shape optimization is proposed to obtain the desired final shape of forming and forging products in the manufacturing process. The final shape of a forming product depends on the shape parameters of the initial blank shape. The final shape of a forging product depends on the shape parameters of the billet shape. Shape optimization can be used to determine the shape of the blank and billet to obtain the appropriate final forming and forging products. The equivalent static loads method for non linear static response structural optimization (ESLSO) is used to perform metal forming and forging optimization since nonlinear dynamic analysis is required. Stress equivalent static loads (stress ESLs) are newly defined using a virtual model by redefining the value of the material properties. The examples in this paper show that optimization using the stress ESLs is quite useful and the final shapes of a forming and forging products are identical to the desired shapes.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.1
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• pp.1-10
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• 2011

An optimization method is proposed for preform and billet shape designs in the forging process by using the Equivalent Static Loads (ESLs). The preform shape is an important factor in the forging process because the quality of the final forging is significantly influenced by it. The ESLSO is used to determine the shape of the preform. In the ESLSO, nonlinear dynamic loads are transformed to the ESLs and linear response optimization is performed using the ESLs. The design is updated in linear response optimization and nonlinear analysis is performed with the updated design. The examples in this paper show that optimization using the ESLs is useful and the design results are satisfactory. Consequently, the optimal preform and billet shapes which produce the desired final shape have been obtained. Nonlinear analysis and linear response optimization of the forging process are performed using the commercial software LS-DYNA and NASTRAN, respectively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.11a
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• pp.43-49
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• 2002

A7003 alloy has characteristics of their excellent weldability, high corrosion resistance and superior plastic working however the broadening of application for the alloy has been hampered by the lower extrudability associated by Mg content. For improvement of extrudability and enhanced recovery efficiency during Al scrap recyeling, it has been generally practiced to reduce Mg content in A7003 alloy. Therefore, it is necessary to investigate the influence of Mg content on mechanical strength and extrudability of A7003 alloy. For efficient material processing which has small amounts, life cycle assessment in material processing(MLCA) is evaluated. The quantitative analysis of energy requirements and $CO_2$ emission for production of A7003 extruded bar are estimated with different Mg content and billet pre-heating process (heating source by light oil or LPG). In particular, the estimation of energy requirements was performed within shipping and gating range (except the mining and extraction stages)to investigate the influence of the variables on energy requirements and $CO_2$ emission in detail. As Mg content increased, the flow stress and the extrusion pressure for A7003 alloy increased. It has been thought that an increment in extrusion pressure with increasing Mg content is caused by the solid solution hardening of Mg atoms in the matrix and increment in volume fraction of intermetallic compound, $Mg_2Si$. The extrudability and the tensile strength are equal to, or above that of conventional A 7003 alloy even the content of Mg varied from $1.1wt.\%\;to\;0.5wt.\%$ alloy. This means that minimizing the content of Mg in A7003 alloy can enhance recovery efficiency during Al scrap recycling. It can be quoted that rather than Mg content energy source for billet heating is a prime factor to determine the atmospheric $CO_2$ emission.