• 소성∙가공
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• 제9권4호
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• pp.362-371
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• 2000

In order to reduce weight of a high-speed railroad vehicle, the main body has been manufactured by hollow section extrusion using aluminum alloys. A porthole die has utilized for the hollow section extrusion process, which causes complicated die geometry and flow characteristics. Design of porthole die is very difficult due to such a complexity. The three-dimensional finite element analysis for hollow section is also an arduous job from the viewpoint of appropriate mesh construction and tremendous computation time. In the present work, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain, is implemented for the analysis of the hollow section extrusion process. In addition, a modified grid-based approach with the surface element layer is utilized lot three-dimensional mesh generation of a complicated shape with hexahedral elements. The effects of porthole design are discussed through the simulation for extrusion of an underframe part of a railroad vehicle. An experiment has also been carried out for the comparison. Comparing the velocity distribution at the outlet with the thickness variation of the extruded part, it is concluded that the analysis results can provide reliable measures whether the die design is acceptable to obtain uniform part thickness. The analysis results are then successfully reflected on the industrial porthole die design.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 추계학술대회 논문집
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• pp.74-77
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• 2000

Porthole die extrusion has a great advantage in the forming of hollow section tubes difficult to produce by conventional extrusion with a mandrel on the stem. Because of the complicated structure of die assembly, extrusion process as a forming of hollow section tubes has been investigated experimentally Therefore, analytic approaches that are useful in profitable die design and in the improvement of productivity are inevitably demanded Welding strength is affected by many parameters, which are such as extrusion ratio, extrusion speed, die shape, porthole number, bearing length, billet temperature and mandrel shape. In this paper, the parameters, which are such as billet temperature, bearing length and tube thickness, are examined. The welding pressures are examined through 3D simulation of non steady state and compared with experimental results.

• 소성∙가공
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• 제10권4호
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• pp.311-318
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• 2001

Porthole die extrusion has a great advantage in the forming of long hollow section tubes. It is difficult to produce long hollow section tubes with complicated section by the conventional extrusion process with a mandrel on the stem Because of the limit of the length of mandrel and the complexity of cross section. Porthole die extrusion is affected by many parameters, such as extrusion ratio, extrusion speed, die geometry, porthole number, bearing length etc. Up to now, most of studies about porthole die extrusion have been investigated by experiments or steady state FE-analysis. However, in this paper, porthole die extrusion is analysed by the unsteady state 3D FE-simulation. And the result of unsteady state analysis is compared with the experimental result. Also, the surface state of extruded tubes are examined for the various process conditions.

• 대한기계학회논문집A
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• 제24권4호
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• pp.1016-1023
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• 2000

The present work is concerned with three-dimensional finite element analysis of the hollow section extrusion process using a porthole die. The effects of related design parameters are discussed through the finite element simulation for extrusion of a triply-connected rectangular tubular section. For economic computation, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain, is implemented. In order to obtain the uniform flow at the outlet, design parameters such as the hole size and the hole position are investigated and compared through the numerical analysis. Comparing the velocity distribution with that of the original design, it is concluded that the design modification enables more uniform flow characteristics. The analysis results are then successfully reflected on the industrial porthole die design.

• 소성∙가공
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• 제7권4호
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• pp.375-381
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• 1998

This paper presents development of finite element simulation program and analysis of hot extrusion through square dies with a mandrel. The design of extrusion dies is still an art rather than science. Die design for a new extrusion process is developed from through in-plant trials. In the present paper, a three-dimensional steady-state finite element simulation program is developed. Steady-state assumption is used for both the analyses of deformation and temperature. The developed program is effectively used to simulate hollow extrusion of several sections. Distributions of temperature effective strain rate, mean strain rate and mean stress are studied for an effective design of extrusion dies.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1999년도 압출 및 인발 심포지엄
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• pp.5-8
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• 1999

The present work is concerned with three-dimensional finite element analysis of the hollow section extrusion process using a porthole die. For economic computation, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain, is implemented. The proposed method improves the computational efficiency significantly, especially fur the three-dimensional analysis of extrusion problems. As a numerical example, extrusion of the underframe part of a railroad vehicle are analyzed. For three-dimensional mesh generation of a complicated shape with hexahedral elements, a modified grid-based approach with the surface element layer is utilized. The analysis results are then successfully reflected on the industrial porthole die design.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1996년도 추계학술대회논문집
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• pp.14-19
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• 1996

This study presents development of finite element simulation program and analysis of hot extrusion through square dies with mandrel. The design of extrusion dies is still an art rather than science. Die design for a new extrusion is developed from through in-plant trials. In the present paper, three-dimensional steady-state finite element simulation program is developed. The developed system is effectively used to simulate extrusion of clamp shaped hollow section. The objective of the present paper is to study the possibility of integrating this method into the design of dies for extrusion of complex section. To obtain sound product, the distributions and effects of temperature, effective strain rate, mean strain rate and mean stress are studied.

• 소성∙가공
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• 제10권6호
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• pp.485-492
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• 2001

The paper is concerned with plastic flow in the port and welding chamber of rectangular hollow section extrusion through the porthole die. The extrusion process is analyzed by numerical simulation and experiments in the unsteady state. The effects of types of inlet with and without taper on the flow and extrusion load are mainly discussed and compared by FEA and experiments. Experiments are carried out by using the plasticine as a model material at room temperature. To visualize the plastic flow in the extrusion process, some split dies and punches are designed and manufactured by EDM. The theoretical predictions by FEM are reasonable agreements with experimental results on the deformed configurations and welding lines.

• 한국기계가공학회지
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• 제4권1호
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• pp.24-29
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• 2005

The development of an aluminum bumper is required in order to reduce the weight of the automobile. An porthole die extrusion process is simulated by the finite element method in order to develop the aluminum bumper which is manufactured by hollow section extrusion. The general-purpose finite element analysis software is used. The developed analysis method can be applied to the optimization of the porthole die extrusion process for the aluminum bumper.

• 한국전산구조공학회논문집
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• 제16권2호
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• pp.133-140
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• 2003

샌드위치 판은 질량에 비해 높은 강성과 강도를 갖고 있으므로 매우 효율적인 구조재로서 폭넓게 쓰이고 있다. 알루미늄 압출 샌드위치 판의 적절한 설계를 위하여는 역학적 거동 해석이 선행되어야 하나, 아직 이에 대한 연구는 미비한 상태이다. 코어가 채워져 있지 않은 중공 단면(hollow section)인 샌드위치 판의 역학적 거동 해석에는 일반적으로 상세 유한 요소 해석을 하게되나, 이는 모델링과 해석에 많은 시간이 소요된다. 본 논문에서는 트러스(truss) 형상의 심재를 갖는 샌드위치 구조 압출재를 이방성의 판으로 치환하여 해석하는 방법을 제시하였다 적절한 이방성 후판으로의 치환을 위해 등가의 강성을 평가하는 방법을 제안하였으며, 이 등가의 강성을 판 이론에 적용하여 균일 분포 하중을 받는 사변 단순지지 조건의 알루미늄 압출재에 대한 처짐과 응력에 대해 간이 해석식을 개발하였다. 아울러 상용 유한 요소 프로그램을 이용하여 계산한 결과와 비교한 결과 제시한 간이식의 높은 정도와 효율성이 입증되었다.