• Transactions of Materials Processing
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• v.7 no.5
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• pp.496-504
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• 1998

The eccentric extrusion and bending process for the forming of the curved rectangular hollow tube is newly developed. Generally the bending process of hollow tube is the secondary process followed by the extrusion process of the hollow tube from the round billet. So many defects such as wrinkling and the difference of wall thickness can be happened during the secondary bending process. In order to avoid the defects the new process named as "the eccentric extrusion and bending process" is suggested and applied to the U-bending of rectangular hollow tube. In this paper the kinematically admissible velocity field between the dies surface and the internal plug boundary surface s developed for the curving velocity. By the using of this curving velocity field the curvature of extruded products can be calculated with the parameters such as eccentricity dies length friction constant aspect ratio.

• Transactions of Materials Processing
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• v.16 no.7
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• pp.555-560
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• 2007

This paper shows some achievements at bending of extruded aluminum profiles during the extrusion process. The conventional process for the production of bent profiles involves a successive extrusion, stretching, and bending of the profiles. Conventional bending methods can not meet demands far precision and cost-effective production in some cases, due to cross sectional deformation, irregular decrease of tube wall thickness and a complication of the process design. An estimation of spring-back required for precision of the bending radius can not always be achieved by the over bending of the profile. Since the profile is hot during the bending process, the spring-back phenomenon can be avoided. This means that an additional bending process is not necessary. Consequently, flexible bending can be achieved with cost reduction and quality improvement. Experimental tests were completed to study the relationship between curvature radius of profile and position of guide on the extrusion for vehicle bumper. A7108 is applied as a billet material in order to increase strength. The overall correlation between the experimental and numerical results is good. It is therefore concluded that the present method provides an efficient means for the constant curvature extrusion process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.102-105
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• 2001

The bending process for the curved tube can be developed by the hot metal extrusion machine with the multiple punches moving in the different velocity. The bending phenomenon has been studied to be occurred by the different of velocity at the die extrusion. The difference of velocity at the die exit section can be obtained by the different velocity of billets through the multi-hole container and by the welding of billets inside the porthole die chamber. The multiple billets are moving differently by the multiple extrusion punches controlled by PLC with the servo mechanism units. The results of the experiments show that the curved tube can be bended by the extrusion process and that the defects such as the distortion of section and the thickness change of thick tube, tile folding and wrinkling of thin tube can not be shown after the bending processing by the extrusion bending machine.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.5
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• pp.502-507
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• 2009

Curvature extrusion process has several advantages in comparison to the conventional extrusion and bending process. In the curvature extrusion, the extruded part is directly bent during extrusion. Therefore, it does not need additional bending process after extrusion. In the curvature extrusion process, it is possible to produce curved extruded products that have a constant or various curvatures. It is essential that we predict the curvatures of the extruded product to meet the required curvatures. This paper proposed a theoretical model that can predict the curvature of extruded product produced by the curvature extrusion process. Using the proposed model the movement of guide tool that causes the bending of extruded product was controlled to produce the required curved automotive Al bumper back beam. The effectiveness of the proposed prediction model and the movement of guide tool were verified by the FE analysis and curved extrusion experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.371-374
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• 2003

The bending process for the "ㄱ" section product can be developed by the hot metal extrusion machine with the two punches moving in the different velocity. The bending phenomenon can be controlled by difference of velocity at the die exit section by the different velocity of billets through the two-hole container. The results of the experiment show that "ㄱ" section product can be bended by the extrusion process and that the curvature of the product can be controlled by the velocity of punch and that the defects such as the distortion of section and the thickness change of the product and the folding and wrinkling of the product did not happen after the bending processing by the extrusion bending machine.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.277-280
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• 2003

It was investigated that the "ㄱ" type angle product could be bended with a curvature during extrusion by extru-bending process. The bending process for the "ㄱ" type angle product can be developed by the hot metal extru-bending machine with the two punches moving in the different velocity. Because of non-symmetry of product, it is important to design the ruled surface contour of dies cavity for the welding and bending with two billets. So it is designed that the multi-hole container has two non-symmetric holes and non-symmetric contour of dies entrance. The results of the experiment show that "ㄱ" type angle product can be bended by the extrusion process and that the curvature of the product can be controlled by the velocity of punch and that the defects such as the distortion of section and the thickness change of the product and the folding and wrinkling of the product did not happen after the bending processing by the extrusion bending machine.

• Transactions of Materials Processing
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• v.14 no.2 s.74
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• pp.160-167
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• 2005

In the present study about extru-bending of angle product, the bending of extruded angle products with the $'\Lambda'$ section and 'ㄱ', section can be obtained using two extrusion billets by the hot metal extru-bending machine with the two punches moving in the different velocity. The bending curvature can be controlled by the different velocity of billets through the two-hole container. This paper describes simulations and experiments of extru-bending process that can make bending during extruding by the difference of stem velocities. And they are applied to two kinds of dies, that is, one of them is conical dies with symmetry $'\Lambda'$ section and the other one is conical dies with asymmetry 'ㄱ' section. The results of the forming simulation by $DEFORM^{TM}-3D$ and results of experiments show that the bending phenomenon at the die exit during extrusion can be obtained with two extrusion billet by the two stems moving in the different velocity. And it was known that it is possible to design the structure of conical cavity of extrusion dies and to control the curvature of product through the simulation and experiment of extru-bending process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.11a
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• pp.63-70
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• 2002

The purpose of the present study is to propose a new way of manufacturing curved metal tubes with arbitrary sections and way of eliminating the conventional bending defects such as thinning and thickening, in the wall of tube, distortion of the section, and wrinkling and folding on the surface by the extrusion bending process that can extrude and weld together one or more billets inside dies cavity, and can bend them during extrusion due to the gradient of extrusion velocities controlled by the eccentricity of the cavity sections between the entrance and the exit of the eccentric conical extrusion bending dies and conical plug, or by the relative size of the holes of multi-hole container, or by the relative moving velocity of multi-punches.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.115-118
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• 1999

The twisting and bending extrusion process is developed by the $DEFORM^TM$-3D. Because the rectangular section of the extruded product has the symmetry line of cross-section area, the twisting and the bending of extruded product has not occurred. The product with the rectangular section is applied to the twisting and bending extrusion process through the twisted die surface and eccentricity die section. It is shown that the twisting of extruded product is caused by the twisted die surfaces and the bending of extruded product is causd by the eccentricity between the die section. The results by the analysis show that the twisting angle and the curvature of extruded products increases by the die twisting angle, the eccentricity, but decreases by the die length, and friction condition

• Journal of the Korean Society for Precision Engineering
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• v.26 no.2
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• pp.71-77
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• 2009

In the automotive industry, aluminum is widely used to reduce the vehicle weight. Aluminum curved extruded components are used for the design of frame parts. This study investigates the curvature extrusion process to produce the aluminum curved suspension arm. In the curvature extrusion process, the bending process is simultaneously carried out with the extrusion process. Firstly, porthole extrusion was investigated by using FE analysis to produce aluminum suspension arm. And then the bending process condition was determined to produce the final suspension arm with the required curvature. In this research, the guide roll movement causes the bending of extruded product. The moving distance and velocity of guide roll were controlled to meet the required curvature of suspension arm. Finally, the curved suspension arm was manufactured by the curvature extrusion experiment under the proposed curvature extrusion condition.