• Transactions of Materials Processing
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• v.1 no.1
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• pp.52-65
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• 1992

In this study a new simplified three-dimensional numerical method and the associated computer program have been developed to simulate the non-axisymmetric extrusion processes. The two-dimensional rigid-plastic finite element method under the generalized plane-strain condition is combined with the slab method. To define the die geometry for a non-axisymmetric extrusion. area mapping technique was used. Streamlined die surface was used to minimize the total extrusion pressure. Extrusion of square, hexagonal and 'T' section from round billet have been simulated and experimented with a model material. The computed results were in good agreement with the experiments in cross-sectional grid distortion. Computational results will be valuable for designing tool geometries and corresponding processes.

• Korea-Australia Rheology Journal
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• v.13 no.2
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• pp.97-106
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• 2001

Three-dimensional flow analysis was performed by using the control volume finite-element method for design of a profile extrusion die. Because polymer melt behavior is complicated and cross-sectional shape of the profile extrusion die is changing continuously, the fluid flow within the die must be analyzed three-dimensionally. A commercially available polypropylene is used for theoretical and experimental investigations. Material properties are assumed to be constant except for the viscosity. The 5-constant modified Cross model is used for the numerical analysis. A test problem is examined in order to verify the accuracy of the numerical method. Simulations are performed for conditions of three different screw speeds and three different die temperatures. Predicted pressure distribution is compared with the experimental measurements and the results of the previous two-dimensional study. The computational results obtained by using three dimensional CVFEM agree with the experimental measurements and are more accurate than those obtained by using the two-dimensional cross-sectional method. The velocity profiles and the temperature distributions within several cross-sections of the die are given as contour plots.

• Korean Journal of Food Science and Technology
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• v.16 no.4
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• pp.429-436
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• 1984

To expand the utility of barley the experiments on the extrusion characteristics of barley flour for snack processing were carried out and the effects of the extrusion conditions on the quality of the extrudates were investigated. The optimum moisture content of barley flour for snack processing was 20%. The moisture content and the density of the extrudates decreased with increasing extrusion temperature and decreasing die size. The die swell ranged from 0.98 to 2.18 according to various extrusion conditions and decreased with increasing temperature above $150^{\circ}C$. The lightness, redness and yellowness increased at higher temperature. The water absorption index and the water solubility index showed their maximum values at $180^{\circ}C$.The gelatinization degree of the extrudates increased with increasing temperature. The fracture fore, Young's modulus and maximum fiber stress decreased, but the deformation to fracture increased, with increasing temperature and decreasing die size. The yield force in puncture test showed lower values at higher temperature. The size and the fraction of the air cells increased with increasing temperature and decreasing die size. The optimum extrusion conditions of barley for snack processing were at the temperature of $180^{\circ}C$, with the die size of 4.5mm when processed at 160 rpm.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.757-758
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• 2012

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.10a
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• pp.7-13
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• 1996

The kinematically admissible velocity field is developed for the analysis of extruded products. The curving of product in extrusion is caused by the linearly distributed longitudinal velocity on the cross-section of the workpiece at the die exit. In the analysis, the longitudinal velocity in extrusion direction is divided into the uniform velocity and the deviated velocity. In order to satisfy the requrement of the kinematically admissible velocity field, the average value of the deviated velocity should be zero. At the same time, it should linearly change with the distance form the center of gravity of the cross-section of the workpiece. The results of the analysis show that the curvature of product increses with increses in eccentricity of gravity center of the cross-section of workpiece at die entrance form that of the cross-section at the die exit. In the analysis, the longitudinal velocity in extrusion direction is divided into the uniform velocity and the deviated velocity. In order to satisfy the requrement of the kinematically admissible velocity field, the average value of the deviated velocity should be zero. At the same time, it should linearly change with the distance from the center of gravity of the cross-section of the workpiece. The results of the analysis show that the curvature of product increses with increses in ecentricity of gravity center of the cross-section of workpiece at die entrance from that of the cross-section at the die exit.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.235-239
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• 1994

In this paper, the fatigue behaviour of typical axisymmetric forward extrusion die is investigated and extrusion process is analyzed by the rigid-plastic finite element method and elasto-plastic finite element method. To approach the crack problem involving crack initiation and propagation in extrusion die, LEFM(Linear Elastic Fracture Mechanics) is introduced and singular element which models stress.strain singularity in the crack tip vincity has been used to obtain an accurate stress intensityu factor values and other results. Form the displacement around the crack tip the stress intensity factor and the effective stress intensity factor at the beginning of the die inlet radius has been calculated. Applying proper fatigue crack propagation criterion such as Paris/Erdogan fatigue law to this data the angle and direction of fatigue crack growth has been simulated and these are compared with some experimental results. Using the computed crack growth rate, fatigue life of the extrusion die has been evaluated.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.11
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• pp.106-113
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• 1996

Using stainless steel as the cold forged parts especially the outer parts of automobile is gradually increasing because it can bear up against the erosion and the wear. During cold forging of the stainless steel the working pressure acting on die surface are very high therefore the wear on die surface can be greatly increased. In cold forging processes, die failure must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The die wear affects the tolerances of forged parts, metal flow and costs of processes etc. The only way to to control these failures is to develop methods which allow prediction of the die wear and which are suited to be used in the desing stage in order to optimize the process. In this paper, the rigid-plastic finite element method was combined with the wear prediction routine and then the forward extrusion process using stainless steel was analysed simultaneously. To minimize the die wear the FPS algorithm was applied and the optimal conditions of die configuration are suggested.

• 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.33 no.7
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• pp.673-680
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• 2009

In this study, die cooling system using the nitrogen gas has been applied to hot aluminum extrusion process for refining grains and reducing of grain growth. Computational fluid dynamics(CFD) has been carried out to evaluate die cooling effect by nitrogen gas, and the results of CFD have been used to FE-simulation for the prediction of the extrudate temperature in hot extrusion process. Experimental hot extrusion has been performed to observe microstructure and to measure temperature of extrudate. The results of FE-Simulation have been good agreement with those of experiment. Finally, process condition of hot extrusion can be established to reduce grain growth of Al6061 through the experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.110-113
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• 2008

This study was performed to predict the shape of polymer extrusion product and to find the cause of defective products Experiments was performed to extrude the complex profile shape using PC/ABS composite resin with new profile die and cooling die. A finite element analysis for the Polymer Extrusion process considering the heat transfer and thermal deformation was also performed, and the result was compared with the experimental data. It is found that the predicted profile shape in F. E. M was similar to the experimental result and the thickness of extruded product was thin when the velocity of profile die outlet was slow than the velocity of production (2m/min).