• Korean Journal of Materials Research
• /
• v.21 no.1
• /
• pp.39-45
• /
• 2011

In this study, the heat flow of the plant scale aluminum extrusion process was investigated to establish optimum continuous heat treatment conditions. During the extrusion of 6061 aluminum alloy, processing parameters such as the extrusion pressure, speed and temperature histories of billets were logged as a function of time. The surface temperature of the billets increased at constant ram speed, while it decreased with decreases of the ram speed. In order to maintain the billet temperature within a solutionizing temperature range prior to the succeeding water quenching step, the ram speed or the temperature of the blower should be controlled. The temperature histories of the billets during the extrusion and hot air blowing processes were successfully simulated by using the velocity boundary model in ANSYS CFX. The methodology to design an optimum process by using a commercial simulation program is described in this study on the basis of the metallurgical validation results of the microstructural observation of the extrudates. The developed model allowed the advantages of taking into account the motion of the extrudate coupled with the temperature change based on empirical data. Calculations were made for the extrudate passing through the isothermal chamber maintained at appropriate temperature. It was confirmed that the continuous heat treatment system is beneficial to the productivity enhancement of the commercial aluminum extrusion industry.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2001.11a
• /
• pp.99-106
• /
• 2001

The design for cold extrusion dies is very important, because the die insert is subjected to very high radial and hoop stresses. The design of cold extrusion dies has many constrained conditions. In this paper, the used assumptions are such that the yield strength of each ring is selected according to the allowable tensile or compressive hoop stress in each ring and the maximum allowable inner pressure, when yielding occurs in one ring of the dies, is obtained by the proposed equation. In order to obtain design variables, such as diameter ratios and interferences, using the maximum inner pressure, the flexible tolerance method was used for shrink-fitted thick-walled cylinders. ANSYS APDL was used to perform the repeated analysis of deformation of the dies due to the variation of the design variables. The response surface methodology is utilized to analyze the relationship between the design variables and the maximum radial displacement of the die insert during extrusion. From the results, it is found that outer diameter of the die Insert has the largest effect on the minimization of maximum radial displacement at the inner surface of the dies.

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

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.4
• /
• pp.22-28
• /
• 2000

By using the finite element method, the Oyane's ductile fracture integral I was calculated from the histories of stress and strain according to every element and then the forming limit of hydroforming process could be evaluated. The fracture initiation site and the forming limit for two typical hydroforming processes, tee extrusion and bumper rail under different forming conditions are predicted in this study. For tee extrusion hydroforming process, the pressure level has significant influence on the forming limit. When the expansion area is backed by a supporter and bulged, the process would be more stable and the possibility of bursting failure is reduced. For bumper rail, the ductile fracture integral i is not only affected by the process parameters, but also by the shape of preforming blank. Due to no axial feeding on the end side of the blank, the possibility of cracking in hydroforming of the bumper rail is influenced by the friction condition more strongly than that of the tee extrusion. All the simulation results show reasonable plastic deformation, and the applications of the method could be extended to a wide range of hydroforming processes.

• Journal of the Korean Society for Precision Engineering
• /
• v.22 no.1
• /
• pp.167-174
• /
• 2005

The design for cold extrusion dies is very important, because the die insert is subjected to very high radial and hoop stresses. The design of cold extrusion dies has many constrained conditions. In this paper, the used assumptions are such that the yield strength of each ring is selected according to the allowable tensile or compressive hoop stress in each ring and the maximum allowable inner pressure, when yielding occurs in one ring of the dies, is obtained by the proposed equation. In order to obtain design variables, such as diameter ratios and interferences, using the maximum inner pressure, the flexible tolerance method was used for shrink-fitted thick-walled cylinders. ANSYS APDL was used to perform the repeated analysis of deformation of the dies due to the variation of the design variables. The response surface methodology is utilized to analyze the relationship between the design variables and the maximum radial displacement of the die insert during extrusion. From the results, it is found that outer diameter of the die insert has the largest effect on the minimization of maximum radial displacement at the inner surface of the dies.

• Journal of Microbiology and Biotechnology
• /
• v.16 no.11
• /
• pp.1678-1683
• /
• 2006

A novel suspension-phase enzyme reaction system for the intermolecular transglycosylation of L-ascorbic acid into 2-O-${\alpha}$-D-glucopyranosyl L-ascorbic acid supplementing extrusion starch as the glycosyl donor was developed using cyclodextrin glucanotransferase from Thermoanaerobacter sp. A high conversion yield compared to the conventional soluble-phase enzyme reaction system using cyclodextrins and soluble starch was achieved. The optimal reaction conditions were 2,000 units of cycIodextrin glucanotransferase, 20 g/l of L-ascorbic acid, and 50 g/l of extrusion starch at $50^{\circ}C$ for 24 h. The new suspension-phase enzyme reaction system also exhibited several distinct advantages other than a high conversion yield, including a lower accumulation of oligosaccharides and easily separable residual extrusion starch by centrifugation or filtration in the reaction mixture, which will facilitate the purification of 2-O-${\alpha}$-D-glucopyranosyl L-ascorbic acid. The new suspension-phase enzyme reaction system seems to be potentially applicable as the industrial process for the production of thermally and oxidatively stable 2-O-${\alpha}$-D-glucopyranosyl L-ascorbic acid.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1999.05a
• /
• pp.24-37
• /
• 1999

A comprehensive methodology to consolidate the hypereutectic Al-27Si-X alloy via spray forming was investigated in an attempt to judge the feasiblilty of this alloy in applying wear resistant components. Billets having desired shape and microstructures were fabricated using forming parameters obtained from numerical calculations. Prior to tube extrusion of the spray formed billets, effects of various extrusion conditions, such as extrusion ratio, die temperature, and die configuration, on microstructures of the billet were studied. Based on results obtained from the preliminary extrusion tests, the formed billets were then hot extruded into a tubular shape. Various material properties of the extruded billet were measured and compared with the other candidate materials for anti-wear applications.

• Transactions of Materials Processing
• /
• v.1 no.1
• /
• pp.66-74
• /
• 1992

According to the variation of hydrostatic pressure on the central axis of deformable material, the V-shaped central bursting defect may be created in extrusion or drawing processes. The process factors which affect the generation of defects are semi-angle of die, reduction ratio of cross-sectional area, friction factor, material properties and so on. The combination of these factors can determine the possibility of defect creation and the shape of various round holes which have been created inside already. By the rigid plastic finite element method, this paper describes the observations of change in shape of round holes with process conditions such as semi-angle of die, reduction ratio of cross-sectional area and friction factor at the non-steady state of axisymmetrical extrusion process when the round hole is already existed inside the original billet. Also, the effects of process factors are investigated to prevent the possible defects.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2007.10a
• /
• pp.132-135
• /
• 2007

In this study, hydroformability and mechanical properties of pre- and post- heat treated Al6061 tubes at different extrusion type were investigated. For the investigation, as-extruded, full annealed and T6-treated Al6061 tubes at different extrusion type were prepared. To evaluate the hydroformability, uni-axial tensile test and free bulge test were performed at room temperature and $250^{\circ}C$. Also mechanical properties of hydroformed part at various pre- and post-heat treatments were estimated by tensile test. And the tensile test specimens were obtained from hexagonal prototype hydroformed tube at $250^{\circ}C$. As for the heat treatment, hydroformability of full annealed tube is 25% higher than that of extruded tube. The tensile strength and elongation were more than 330MPa and 12%, respectively, when hydroformed part was post-T6 treated after hydroforming of pre- full annealed tube. However, hydroformed part using T6 pre treated tube represents high strength and low elongation, 8%. Therefore, the T6 treatment after hydroforming for as-extruded tube is cost-effective. Hydroformability of Al6061 tube showed similar value for both extrusion types. But flow stress of seam tube showed $20{\sim}50MPa$ lower value.

• Journal of Biosystems Engineering
• /
• v.30 no.5 s.112
• /
• pp.285-292
• /
• 2005

Extrusion process and physical properties of extrudates of pulp powder (TMP, thermomechanical pulp fibers) mixed with expanding additives was evaluated to develop biodegradable packaging materials. To find out the optimum condition, the status of extrusion process, coefficient of elastic and expansion ratio of extrudates were tested on the composites (wheat flour, soluble starch, polyvinyl alcohol), blending conditions of composites and moisture contents of extrudates. In case of material composition, wheat flour played a key role to keep extrusion process irrespective of the added amounts of soluble starch and polyvinyl alcohol. The coefficient of elastic of extrudates was increased and the expansion ratio was reduced as the added amounts of wheat flour increased. Also, the coefficient of elastic of extrudates was decreased as the moisture content of extrudates increased. The lowest coefficient of elastic was 439.55 kPa under the condition, of pulp powder mixed with $20\%$ of wheat flour based on pulp weight and $10\%$ of soluble starch based on wheat flour weight and controlled $20\%$(wb) of moisture content.