• Transactions of Materials Processing
• /
• v.8 no.5
• /
• pp.520-526
• /
• 1999

In this study a practical formula based on the experime수 랙 the estimation of load in the non-circular tube extrusion with the mandrel is proposed by using the effective extrusion ratio. Through some experiments for the several shaped sections, the coefficients of the empirical equation are determined by ticine as a model material at room temperature. The proposed empirical formula for the estimation of extrusion load will be applicable to the non-steady state as well as steady state for the extrusion of various shaped tubes from hollow billets.

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.10
• /
• pp.77-82
• /
• 2000

The design of the prestressed cold extrusion die with two stress rings has been performed in this study. The cold extrusion has been simulated by the rigid-plastic FEM. The stress analysis of die has been performed for both after shrink fitting and during extrusion by using the elastic FEM and the Lame's equation. According to the variation of interferences and diameter ratios, the maximum effective stress has been evaluated. As results, interferences and diameters were determined by the minimization of the maximum effective stress of die insert. The comparison of the maximum effective stress between the proposed design and the conventional design has been discussed. It was found that the maximum effective stress in the die insert is considerably affected by the stiffness of the first stress ring.

• Journal of Environmental Science International
• /
• v.16 no.10
• /
• pp.1169-1177
• /
• 2007

The main objective of this research was to evaluate the effects of process variables which were forming ability, flow displacement, effective stress, effective strain, fluid vector and products defects on manufactured artificial lightweight aggregate made of both incinerated sewage sludge ash and clay by means of the numerical analysis of a rigid-plastic finite element method. CATIA (3D CAD program) was used for an extrusion metal mold design that was widely used in designing aircraft, automobile and metallic molds. A metal forming analysis program (ATES Co.) had a function of a rigid-plastic finite element method was used to analyze the program. The result of extrusion forming analysis indicated clearly that a shape retention of the manufactured artificial light-weight aggregate could be maintained by increasing the extrusion ratio (increasing compressive strength inside of extrusion die) and decreasing the die angle. The stress concentration of metal mold was increased by increasing an extrusion ratio, and it was higher in a junction of punch and materials, friction parts between a bottom of the punch and inside of a container, a place of die angle and a place of die of metal mold. Therefore, a heat treatment as well as a rounding treatment for stress distribution in the higher stress concentration regions were necessary to extend a lifetime of the metallic mold. A deformity of the products could have made from several factors which were a surface crack, a lack of the shape retention and a crack of inside of the products. Specially, the surface crack in the products was the most notably affected by the extrusion ratio.

• Transactions of Materials Processing
• /
• v.16 no.8
• /
• pp.614-620
• /
• 2007

Deformation characteristics and damage evolution during warm backward extrusion of bulk AZ31 Mg alloy were investigated using finite element analyses. AZ31 Mg alloy was assumed as a hardening viscoplastic material. The tensile tests of AZ31 Mg alloy in previous experimental works showed the ductile fracture even at the warm temperature of $175^{\circ}C$. In this study, damage evolution model proposed by Lee and Dawson, which was developed based on the growth of micro voids in hardening viscoplastic materials, was combined into DEFORM 2D. Effects of forming temperature, punch speed, extrusion ratio and size of work piece on formability in warm backward extrusion as well as on mechanical properties of extruded products were examined. In general, finite element predictions matched the experimental observations and supported the analyses based on experiments. Distributions of accumulated damage predicted by the finite element simulations were effective to identify the locations of possible fracture. Finally, it was concluded that the process model, DEFORM2D combined with Lee & Dawson#s damage evolution model, was effective for the analysis of warm backward extrusion of AZ31 Mg alloys.

• Transactions of Materials Processing
• /
• v.24 no.6
• /
• pp.425-430
• /
• 2015

In the current paper, the effects of initial slug design on the earring of an Al rectangular battery case manufactured by impact extrusion were studied. During impact extrusion, non-uniform metal flow between the long and the short sides of the battery case leads to earring, which is subsequently trimmed. Process parameters such as friction, aspect ratio of the battery case, the die shape and the forming temperature tend to induce earring because they cause greater non-uniform metal flow. Large aspect ratio of the battery case and high friction between slug and die can greatly affect the earring of a rectangular battery case. To make a rectangular battery case without earring, it is necessary to control metal flow uniformly during impact extrusion. One of the ways to reduce the earring is to control the metal flow of slug at the initial upsetting stage. To analyze the effects of the initial slug design on earring, FE analysis was conducted using DEFORM 3D. Two types of initial slug designs were evaluated where volume was removed along either the width or thickness directions. The results show that the initial slug design can be effective in adjusting the uniformity of metal flow.

• Journal of the Korean Society of Marine Environment & Safety
• /
• v.5 no.2
• /
• pp.27-33
• /
• 1999

The present study is concerned with the hydrostatic extrusion process of copper-clad aluminum rod through metallurgical joining. In this study, the rigid plastic finite element program, HICKORY, is used to analyze the steady state extrusion process of the bimetal rod. Simulations are performed for copper-clad aluminum rod with several extrusion ratio to give the distributions of effective strain rate, equivalent stress and hardness. Experiments are also carried out for aluminum-inserted copper rod at room temperature. It is found out that finite element predictions are generally in good agreement with the experimental observations. The detail comparison of the extrusion loads by the finite element method with those by experiments are given.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2006.05a
• /
• pp.247-250
• /
• 2006

The growing demand for more fuel-efficient vehicles to reduce energy consumption and air pollution is a challenge for the automotive industry. The characteristic properties of aluminum, high strengrth stiffness to weight ratio, good formability, good corrosion resistence, and recycling potential make it the ideal candidate to replace heavier materials in the car to respond to the weight resuction demand within the automotive industry. In this paper, A series of compression test was carried out to find the flow stress of A6082 at 300, 400 and $500^{\circ}C$, then we tried to estimate weldability, extrusion load and effective stress of die in the aluminum extrusion process through the 3D FE simulation at non-steady state for aluminum automotive parts.

• Proceedings of the Korean Powder Metallurgy Institute Conference
• /
• 2006.09a
• /
• pp.325-326
• /
• 2006

Using $6wt%Y_2O_3-2wt%Al_2O_3$ as sintering additives and Si as a raw powder, the continuously porous in-situ $Si_2N_2O-Si_3N_4$ bodies were fabricated by multi-pass extrusion process and their microstructures were investigated depending on the addition of carbon (0-9wt%) in the mixture powder. The introduction of $Si_2N_2O$ fibers observed in the unidirectional continuous pores as well as in the pore-frame regions of the nitrided bodies can be an effective method in increasing the filtration efficiency. In the case of no carbon addition, the network type $Si_2N_2O$ fibers with high aspect ratio appeared in the continuous pores with diameters of 150-200 nm. However, in the case of 9wt% C addition, the fibers were found without any network type and had diameters of 200-250 nm.

• Journal of the Korean Society for Precision Engineering
• /
• v.21 no.1
• /
• pp.32-39
• /
• 2004

Traditional forging of a hollow T-shaped part has been applied to forge a solid T-shaped product from a solid billet and then to machine the hollow in that. In a case, a hollow T-shaped part can be forged by backward-extruding from a solid billet. In this study, four types of forging were suggested for manufacture of hollow T-shaped parts. Forging simulations for each of these forging methods were carried out to investigate folding defect, metal flow pattern, effective strain, and forging loads. Experimental works were carried out to be compared with the simulation results. Here, the ratio of the thickness of the hollow tube to that of the flange was selected to investigate a forging defect like folding.

• Journal of the Korea institute for structural maintenance and inspection
• /
• v.8 no.1
• /
• pp.183-194
• /
• 2004

It's essential process to study non-linear material function related to characteristics of compressibility and permeability when we predict the consolidation behavior of soft clay ground. In this study, laboratory tests were conducted to find out the material function using marine clay. Standard oedometer test and Rowe cell test were performed with conditions, which were classified into vertical drainage only, radial drainage only and vertical-radial drainage case. Modified oedometer test equipment was developed to find out the material function and special extrusion device was originated to minimize the sample disturbance effect. Reliability of the results in modified oedometer test could be confirmed by comparing with the Rowe cell's one. Effective stress - void ratio - permeability relations were analyzed using all testing results. As a result, void ratio with effective stress level could be expressed by the power function and permeability with void ratio could be expressed by exponential function. In soft clay with high initial water content and low shear strength, non-linear characteristics related to compressibility and permeability varied with wide range by the effective stress levels. It's important to note that non-linearity of the material function should be considered at prediction of the consolidation behavior.