• Journal of Korea Foundry Society
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• v.24 no.6
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• pp.331-339
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• 2004

Melt-extrusion process, a metallic melt poured and solidified up to semisolid state in the container can be directly extruded through the die exit to form a product of bar shape without other intermediate processes. In this study, the fabrication characteristics of the process were evaluated with various process parameters, such as preheating temperature of extrusion dies, extrusion temperature and extrusion ratio. AI-Cu alloys were successfully extruded after squeezing out of liquid during melt-extrusion with smaller force compared to the solid extrusion. Soundly AI-Cu alloy bar was fabricated at the preheating temperature of $500{\sim}520^{\circ}C$. The range of extrusion temperature for soundly melt-extruded AI-Cu alloy bar was increased with increasing extrusion ratio. Mechanical properties of melt-extruded AI-Cu alloy bars were found change with Cu content of the melt-extruded bars due to the occurrence of segregation. The various extrusion temperature yielded equiaxed structure with a grains size about 200 ${\mu}m$.

• 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.

• Transactions of Materials Processing
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• v.13 no.5
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• pp.422-428
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• 2004

At present, the design of extrusion dies and operation in extrusion companies are primarily based on trial and error. The experience of the die designer, the press operator and the die corrector determine the performance of the extrusion die and the efficiency of the process. In order to produce defect-free products of desirable quality in terms of strength, surface quality and geometrical dimensions, it is important to obtain more knowledge of the processes that occur during extrusion. Recently, to reduce the costs of designing and manufacturing of extrusion dies, and to ensure the quality of the extruded products, numerical simulation for extrusion processes such as FEM (finite element method) is applied increasingly and becomes a very important tool for the design and development of new products. However, most of the studies about FE simulation have been accomplished for simple geometry and low extrusion ratio in the filed of steady metal flow conditions. The extruded products of AI alloy in industrial practice involve complicated sectional geometry. This study was designed to reduce the time of die design and manufacturing in the extrusion process using FEM simulation. FEM simulations of extrusion process were performed in non-steady states conditions by changing weld plate included in extrusion die set. Product which was employed in this study is heat sink that has been used in the parts of heat exchanger of electric circuits. It is generally applied for aluminum or its alloys due to heat efficiency and easy production of complicated shapes, and manufactured by extrusion process. The simulated results showed that weld plate shape in extrusion dies influences meta] flow and dimensional accuracy of products.

• 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.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.723-730
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• 2004

This paper describes the analysis of extrusion process and integrity for a condenser tube which is a component of the heat exchanger in automobile and all conditioning apparatus. Recently, according to the development of analysis method using the computer, the numerical simulation have been applied to the 3-dimensional hot extrusion process with complex section area of the non-steady statement and then results of the analysis have been applied to optimal die design and process design. In this paper, firstly, the die design was performed for a condenser tube with a multi-hole section and the rigid-plasticity FE analysis performed of extrusion process. Secondly, we estimated metal flow of billet, extrusion load, welding pressure in chamber etc. and evaluated the pressure and elastic strain of the die land and mandrel tooth profile through a stress analysis of the die. Finally, the extrusion test was performed to estimate the validity of FE analysis. This paper confirmed that the designed extrusion die of the research is satisfactorily designed fur integrity of condenser tube.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.4
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• pp.625-632
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• 2012

Optimization of process parameters in polymer extrusion is an important task to reduce manufacturing cost. To determine the optimum values of the process parameters, it is essential to find their influence on the strength of polymer breathable thin film. The significance of six important process parameters namely, extruder cylinder temperature, extruder speed, extruder dies temperature, cooling roll temperature, stretching ratio, stretching roll temperature on breathable film strength of polymer extrusion was determined. Moreover, this paper presents the application of Taguchi method and analysis of variance (ANOVA) for maximization of the breathable film strength influenced by extrusion parameters. The optimum parameter combination of extrusion process was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that extruder speed and stretching ratio were the most influential factor on the film strength, respectively. The best results of film strength were obtained at higher extruder speed and stretching ratio.

• Food Science and Biotechnology
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• v.14 no.3
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• pp.363-367
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• 2005

Although widely applied in the food industry, extrusion cooking has not been applied to the traditional red ginseng process for steaming and drying ginseng. We therefore investigated the change in the effective components in red ginseng (total saponins, ginsenosides and maltol) from extruded raw ginseng. The variables were the drying temperature of the sliced raw ginseng (80 and $90^{\circ}C$) before the extrusion process and the moisture content (15 and 22%, w.b.) during the extrusion process. Ginsenosides Rg1 and Rg2 were detected in dried ginseng at $80^{\circ}C$, but ginsenoside Rg3, which was contained in red ginseng, was not detected. On the other hand, ginsenosides Rg1, Rg2 and Rg3 were detected in extruded ginseng at moisture contents of 15 and 22%. Total ginsenosides were highest at $90^{\circ}C$ drying temperature and 22% moisture content for the extrusion process.

• Transactions of Materials Processing
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• v.14 no.5 s.77
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• pp.444-451
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• 2005

A new extrusion process of the circular section product with helical fins could be developed by rotating extrusion die. The twisting of extruded product is caused by the twisted conical die surface connecting the die entrance section and the die exit section linearly. But, until now, because the process has used fixed extrusion die, it needs high pressure in order to twist billet and form fin shape on the surface of billet. So, during extruding billet, in order not to twist billet, the extrusion die is needed to rotate itself instead of twisting of billet. It is known that it is possible to reduce extrusion load of product with helical fins by analysis and experiments using rotating die. And it is known that, through the extrusion load analysis by $DEFORM^{TM}-3D$ software, optimal rotational velocity of rotating die can be obtained according to reduction ratio of area and twisted angle of die. And experiments and analysis using rotating extrusion die show that the twisted angle of product can be controlled by twisted angle of extrusion helical die and the rotational velocity of extrusion helical die.

• 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.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.499-502
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• 2005

A process map has been developed, which can identify the process conditions for weak mechanical bonding at the contact surface during the direct extrusion of a Cu-Ti bimetal bar. Bonding mechanism between Cu and Ti was assumed as a cold pressure welding. Then, the plastic deformation at the contact zone causes mechanical bonding and a new bonding criterion for pressure welding was developed as a function of the principal stretch ratio and normal pressure at the contact surface by analyzing micro local extrusion at the contact zone. Finite element analyses for extrusion of Cu-Ti bimetal bars were performed for various process conditions. The deformation history at the contact surface was traced and the proposed new bonding criterion was applied to predict whether the mechanical bonding at the Cu-Ti contact surface happens. Finally, a process map for the extrusion of Cu-Ti bimetal bar is suggested.