• Title/Summary/Keyword: Extrusion forming analysis

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Numerical and Experimental Investigation on the Tube Forming in the Radial-Forward Extrusion

  • Ko Beong-Du;Jang Dong-Hwan;Choi Ho-Joon;Hwang Beong-Bok
    • International Journal of Precision Engineering and Manufacturing
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    • v.6 no.2
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    • pp.26-33
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    • 2005
  • In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effect of process variables such as gap height, relative gap width and die comer radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.

Numerical and Experimental Investigation on the Tube Forming in the Radial-Forward Extrusion (레이디얼-전방압출에서 튜브성형에 관한 해석 및 실험)

  • 고병두;장동환;최호준;황병복
    • Journal of the Korean Society for Precision Engineering
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    • v.20 no.12
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    • pp.168-175
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    • 2003
  • In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effects of process variables such as gap height, relative gap width and die corner radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.

Forming Analysis and Experiment of Hard to Forming T Shape Aluminum Part (난성형 T형상 알루미늄 부품의 성형공정 해석 및 실험)

  • Jin, Chul-Kyu
    • Journal of the Korean Society of Industry Convergence
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    • v.20 no.2
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    • pp.141-148
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    • 2017
  • A process comprising a hot extrusion process and a warm forging process was designed to form a T-shaped aluminum structural component with a high degree of difficulty by the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, and then an embossing part was formed with a warm forging process. The formability and the maximum load required for forming were then determined using a forming analysis program. The hot extrusion process was executed at $450^{\circ}C$ under the extrusion speed at 6 mm/s, while the warm forging process was executed at $260^{\circ}C$ under the forging speed at 150 mm/s. For both the processes, a condition by which friction would not be generated between the mold and the material was implemented. The analysis results showed that the load required for hot extrusion was 1,019 tons, while the load required for the warm forging was 534 tons. The T-shaped part was manufactured by using a 1,600 tons capacity press. The graphite lubricant was coated on the mold as well as the material. A forming experiment was performed under the same condition with the analysis condition. The measured values from the load cell were 1,210 tons in the hot extrusion process and 600 tons in the warm forging process.

An Analysis of Backward Extrusion Process with Torsion (비틀림을 이용한 후방압출 공정의 해석)

  • 허진혁;김영호;박재훈;진영은;이종헌
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2000.11a
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    • pp.846-849
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    • 2000
  • In this paper backward extrusion process with lower die rotation was studied to improve the conventional backward extrusion problems ; requirement of large forming machine, the difficulty to selecting of die material caused by high surface pressure, high cost of forming machine caused by improvement of noise and vibration, and etc. In this experiment, model material, plasticine, was used of specimen. The result values of torsional and conventional backward extrusions were analyzed and compared. FE-simulation is used for analysis with DEFPRM-3D. These results show that the torsional backward extrusion is very useful process because this process can obtain the homogeneous deformation, low forming load. Decreasing forming load improves die life and makes it possible to use press of relatively low capacity. Also this process can reduce corner cavity, improve the initial cast-structure, owing to the high deformation and uniform starin distribution.

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Analysis on the corner cavity formation in backward extrusion process (후방압출공정의 corner cavity 형성에 관한 해석)

  • 김영호;변홍석
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1995.10a
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    • pp.236-239
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    • 1995
  • In this paper,Upper bound analysis to predict the formation of corner cavity during the final stage of backward extrusion is used. The critical condition for corner cavity formation is obtained by upper bound analysis. The quantitive relationships between corner cavity formation and process parameters are studied. To broaden forming limit area, driven container and multi-step forming process is proposed. As a result of FEM, forming limit is enlarged. And this results is compared with the analytric results

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Characteristics of Forming toad in Forward and Backward Can Extrusion Processes (전ㆍ후방 캔 압출공정의 성형하중특성)

  • Choi H. J;Ham B. S;Ok J. H;Shim J. H;Kim S. H;Hwang B. B
    • Transactions of Materials Processing
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    • v.13 no.8
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    • pp.689-695
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    • 2004
  • This paper is concerned with the analysis of the forming load characteristics of a forward-backward can extrusion process. The analysis in this paper is extended to the selection of press frame capacity for producing efficiently final product at low cost. The possible extrusion processes to shape a forward-backward can part with different outer diameters are categorized to investigate quantitatively the forming load, forming energy and maximum pressure exerted on the die-material interface. The categorized processes are composed of combined and/or some basic extrusion processes. After the analysis of the forming load characteristics, the frame capacity of press suitable for a selected process could be determined along with securing the load capacity and with considering productivity. In addition, it is also suggested that different load capacities be selected for different dimensions of a part such as the wall thickness in forward direction. The work in this paper could be a good reference for analysis of complex extrusion and selection of proper frame capacity of press to achieve low production cost and thus high productivity.

The Forming Limit of Flange in the Radial Extrusion (레이디얼 압출에서 플랜지의 성형한계)

  • 고병두;장동환;최호준;임중연;황병복
    • Transactions of Materials Processing
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    • v.12 no.3
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    • pp.228-235
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    • 2003
  • In this paper, the workability of flange in the radial extrusion is analyzed in terms of the deformation pattern, the punch load and the forming limit by using simulation and experiment. A single action pressing is applied to both simulation and experiment. The analysis in this study is focused on the transient extrusion into the gap in radial direction with various gap heights and die corner radius. Based on the surface strains where surface cracking occurs, the forming patterns and strain-fracture relationships in producing radially extruded flange are obtained.

A Study on the Forming Characteristics of Radial-Forward Extrusion Process (레이디얼-전방압출 공정의 성형특성에 관한 연구)

  • 황승규;이호용;황병복
    • Transactions of Materials Processing
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    • v.11 no.1
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    • pp.84-89
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    • 2002
  • This study is concerned with the analysis of the forming characteristics of radial-forward extrusion. Angle between radial and forward extrusion, gap height, and friction factor are considered as important design factors to affect forming characteristics in radial-forward extrusion. The rigid-plastic finite element method is adopted to analyze the effects of design factors on forming loads. The incremental rates of loads are nearly constant except the deformation zone from radial to forward extrusion. The smaller angle induces lesser force increment, therefore forming load increases as the angle increases. Maximum load also increases as gap-height decreases and friction factor increases.

Effect of the Design Parameter for Internal Spline Forming Using the Tube (중공축 내접 스플라인 성형을 위한 설계변수의 영향)

  • Wang, C.B.;Lim, S.J.;Park, Y.B.
    • Transactions of Materials Processing
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    • v.15 no.7 s.88
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    • pp.512-517
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    • 2006
  • In this paper, the cold extrusion process for internal spline forming using a thin and long tube has been analyzed by using a rigid plastic finite element code. The internal spline consists of 10 tooths. The cold extrusion process has been focused on the comparisions of load-stroke relation and filling states of the teeth according to design parameters. The design parameters involve extrusion ratio, extrusion angle and friction factor. The internal spline forming can cause the buckling and folding during the cold extrusion process because of using a thin and long tube. The optimum design parameters have been obtained through rigid-plastic finite elements analysis. The extrusion ratio and extrusion angle have great effects on the deformation characteristics of the cold extrusion process.

A Study on the Numerical Friction Model for the Extrusion (압출성형을 위한 마찰수식 모델에 관한 연구)

  • Oh P. K.;Kim J. S.;Yu S. K.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2002.11a
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    • pp.15-22
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    • 2002
  • To carry out perfectly the forming analysis of the extruding products, it is necessary that the friction boundary condition between dies and blanks should be worked out the accuate numerical friction models. But the numerical friction models adapting in the conventional Extrusion forming software may be large different from the actual conditions. Expecially, the use of the existing extrusion forming software is possible only in the limitted range owing to the unaccuracy of the high speed forming work. Therefore, tile prepare of this study is to develop the numerical friction model which describes the friction boundary condition mathematically well, to improve the accuracy of the extrusion farming analysis, and finally to expand the applying areas of the results.

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