• Title/Summary/Keyword: Porthole-die

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Die stress and Process of Analysis for Condenser Tube Extrusion according to Chamber Height (접합실 높이변화에 따른 컨덴서 튜브 직접압출 공정 및 금형강도해석)

  • Lee J. M.;Lee S. G.;Kim B. M.;Jo H. H.;Jo H.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2002.11a
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    • pp.33-41
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    • 2002
  • In case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. However, there have been few studies about condenser tube extruded by porthole die. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to variation of chamber length. in porthole die. Estimation was carried out using finite element method. Porthole die is analyzed in as non-steady state. Analytical results provide useful information the optimal design of porthole die.

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Development of Porthole Extrusion Die for Improving Welding Pressure in Welding Chamber by Using Numerical Analysis (수치해석을 이용한 접합실 내 접합압력 향상을 위한 포트홀 압출금형 개발)

  • Lee, S.Y.;Lee, I.K.;Jeong, M.S.;Ko, D.C.;Kim, B.M.;Lee, S.K.
    • Transactions of Materials Processing
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    • v.26 no.2
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    • pp.115-120
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    • 2017
  • Porthole extrusion process is a very effective metal forming process to produce aluminum profiles with hollow sections. The structure of porthole extrusion die is very complex. In this process, the billet is divided by porthole bridge, and then the divided billet is welded in the welding chamber. The welding pressure in the welding chamber is very important. The higher welding pressure improves the quality of the aluminum profiles. Therefore, the objective of this study is to develop a new porthole extrusion die for improving the welding pressure in the welding chamber by using numerical analysis. The effectiveness of the new porthole extrusion die was verified by using numerical analysis. Through numerical analysis, the welding pressures in the welding chamber between the new porthole die and the conventional porthole die were compared with each other.

Unsteady State Analysis of Al Tube Hot Extrusion by A Porthole Die (포트홀 다이에 의한 Al 튜브의 비정상상태 열간 압출 공정 해석)

  • 조형호;이상곤;박종남;김병민
    • Transactions of Materials Processing
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    • v.10 no.4
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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.

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Development of Direct Extrusion Process on Al 1050 Condenser Tube by using Porthole Die (포트홀 다이를 이용한 Al1050 컨덴서 튜브의 직접압출공정 기술 개발)

  • 이정민;김병민;강충길;조형호
    • Journal of the Korean Society for Precision Engineering
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    • v.21 no.7
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    • pp.53-61
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    • 2004
  • Condenser tube which is used for a cooling system of automobiles is mainly manufactured by conform extrusion. However, direct extrusion using porthole die in comparison with conform extrusion has many advantages such as improvement of productivity, reduction of production cost etc. In general, the porthole die extrusion process is useful for manufacturing long tubes with hollow sections and consists of three stages(dividing, welding and forming stages). Especially, Porthole die for producing condenser tube is very complex. Thus, in order to obtain the detailed mechanics, to assist in the design of proper die shapes and sizes, and to improve the quality of products, porthole die extrusion should be analyzed in as non-steady state as possible. This paper describes FE analysis of non-steady state porthole die extrusion for producing condenser tube with multi-hole through 3D simulation in the non-steady state during the entire process to evaluate detailed metal flow, temperature distribution, welding pressure and extrusion load. Also to validate FE simulation of porthole die extrusion, a comparison of simulation and experiment results was presented in this paper.

Die Stress and Process Analysis for Condenser Tube Extrusion according to Chamber Height (접합실 높이에 따른 컨덴서 튜브 직접압출 공정 및 금형강도 해석)

  • Lee, J.M.;Kim, B.M.;Jung, Y.D.;Jo, H.;Jo, H.H.
    • Transactions of Materials Processing
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    • v.12 no.3
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    • pp.214-220
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    • 2003
  • In the case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. There have been few studies about condenser tube extruded by porthole die. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to variation of chamber length in porthole die. The welding chamber height in condenser tube was calculated by using finite element method. Forming analysis results for condenser tube would provide useful information for the optimal design of porthole die.

Design of Porthole Extrusion Die for Improving the Welding Pressure in Welding Chamber by using the FE Analysis and Taguchi Method (유한요소해석 및 다구찌법을 이용한 접합실 내 접합압력 향상을 위한 포트홀 압출 금형 설계)

  • Lee, S.Y.;Lee, I.K.;Jeong, M.S.;Ko, D.C.;Lee, S.K.
    • Transactions of Materials Processing
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    • v.28 no.6
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    • pp.347-353
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    • 2019
  • The porthole extrusion process is a classic metal forming process to produce complex cross-section shaped aluminum profile. It is very difficult to design porthole die and extrusion process because of the complex shape of extrusion die and internal metal flow. The main variables in this process are ram speed, initial billet and tool temperature, and die shape. In general, the metal flow of porthole extrusion process can be divided into two steps. During the first step, the billet is divided into several parts in the porthole die bridge. During the second step, the divided billets are welded in the welding chamber. In the welding chamber, the level of welding pressure is very important for the quality of the final product. The purpose of this study is to increase the welding pressure in the welding chamber by using a two stage welding chamber. The porthole extrusion die was designed by using the Taguchi method with orthogonal array. The effectiveness of the optimized porthole die was verified by using the finite element analysis.

A Study on the Con-focal Microscope for the Surface Measurements (공초점 현미경을 이용한 물체표면 형상측정에 관한 연구)

  • 강영준;송대호;유원재;백성훈
    • Journal of the Korean Society for Precision Engineering
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    • v.20 no.5
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    • pp.73-81
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    • 2003
  • In case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. However, there have been few studies about condenser tube extruded by porthole die. Original metal flow of condenser tube by porthole die extrusion is similar to hollow cylinder extrusion but the estimation of metal flow for extrusion parameters is different. For example, variation of chamber length in hollow extrusion only affects the welding pressure, however, the welding chamber length in condenser tube extrusion influences to the welding pressure as well as the deflection of mandrel. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to angular variation in the bottom of chamber in porthole die. Estimation was carried out using finite element method in as non-steady state. Analytical results can provide useful information the optimal design of porthole die.

The Effect of Chamber Bottom Shape on Die Elastic Deformation and Process in Condenser Tube Extrusion (접합실 바닥형상이 컨덴서 튜브 직접압출 공정 및 금형탄성변형에 미치는 영향)

  • Lee, Jung-Min;Kim, Byung-Min;Jung, Young-Deuk;Cho, Hoon;Cho, Hyung-Ho
    • Journal of the Korean Society for Precision Engineering
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    • v.20 no.5
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    • pp.66-72
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    • 2003
  • In case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. However, there have been few studies about condenser tube extruded by porthole die. Original metal flow of condenser tube by porthole die extrusion is similar to hollow cylinder extrusion but the estimation of metal flow for extrusion parameters is different. For example, variation of chamber length in hollow extrusion only affects the welding pressure, however, the welding chamber length in condenser tube extrusion influences to the welding pressure as well as the deflection of mandrel. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to angular variation in the bottom of chamber in porthole die. Estimation was carried out using finite element method in as non-steady state. Analytical results can provide useful information the optimal design of porthole die.

Die stress and Process of Analysis for Condenser Tube Extrusion by using a Porthole Die (포트홀 다이를 이용한 컨덴서 튜브 직접압출 공정해석 및 금형강도 해석)

  • Lee, J. M.;lee, S. K.;Kim, B. M.;Jo, H. H.;Jo, H.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2002.05a
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    • pp.1030-1033
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    • 2002
  • In this study, it is important that we have an understanding of the metal flow for manufacturing condenser tube in porthole die extrusion, because this need to provide for household appliances market that is expected to grow into the major market of the cooling system hereafter. Condenser tube is mainly manufactured by conform exclusion. However, this method was not satisfied a series of the needs for manufacturing condenser tube as compared with porthole die extrusion. The deforming skill recently is required high-productivity, high-accuracy and reducing lead-time, thus it is essential to substitute conform exclusion by porthole die exclusion. Porthole die extrusion has many advantages such as improvement of productivity, reduction of production cost etc. In general, the porthole die extrusion process consists of three stages(dividing, welding and forming stages). In order to obtain the detailed mechanics, to assist in the design of proper die shapes and sizes, and to improve the quality of products, porthole die extrusion should be analyzed in as non-steady state as possible during the entire process to evaluate detailed metal flow, temperature distribution, welding pressure and extrusion lead, and therm stress analysis was practiced to obtain effective stress and elastic deformation value. A analytical results provide useful information the optimal design of the porthole die for condenser tube.

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Extrusion process Analysis and Evaluation of Mechanical property for Micro Multi Cell Tube with 4 hole (4 홀 Micro Multi Cell Tube 의 압출공정 해석 및 기계적 특성 평가)

  • 이정민;김병민
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2004.10a
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    • pp.397-400
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    • 2004
  • The direct extrusion with porthole die can produce condenser tube which has the competitive power in costs and qualities compared with the existing conform extrusion. In general, porthole die extrusion has a great advantage in the forming that produces the hollow sections difficult to produce by conventional extrusion with a mandrel on the stem. Especially, condenser tube manufactured by porthole die belongs to sophisticated part and demands tighter dimension tolerance and higher surface finish than any other part. In order to confirm the general of porthole die extrusion, we perform the 3D FE analysis of hot porthole extrusion in non-steady state by using DEFORM 3D and investigate a pattern of elastic deformation for porthole die through the stress analysis using ANSYS 5.5 during extrusion process.

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