Analysis and finite element simulation of bimetallic backward rod extrusion
Abstract
In this paper, the process of bimetallic backward rod extrusion through a conical punch, by means of upper bound method and finite element method is investigated. An admissible velocity field is developed and then by calculating the internal, shear and frictional powers, the extrusion force is estimated. The extrusion process is also simulated by using the finite element code, ABAQUS. Analysis and simulations are done for two types of bimetallic rods: aluminium as core, copper as sleeve (Al-Cu) and copper as core, aluminium as sleeve (Cu-Al). The extrusion force from the upper bound method is compared with the finite element results. This comparison shows that the upper bound predictions are in good agreement with the finite element results. The results also show that, the extrusion force in the case of Cu-Al rod is smaller than Al-Cu rod and in both types of bimetallic rods, the aluminium leaves the deformation zone sooner than the copper. Finally the effects of various extrusion parameters, such as the friction factor, reduction in area and semi-punch angle upon the extrusion force are investigated and the optimum semi-punch angle is determined.
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Haghighat and Momeni-Khabisi found an increase of the optimal semi die angles with an increase of the extrusion ratio and friction factor.
“They found an increase of the optimal semi die angles with an increase of the extrusion ratio and friction factor [5].”
From Influence of Die Surface Topography and Lubrication on the Product Quality during Indirect Extrusion of Copper-Clad Aluminum Rods (2020) · cites this paper as [5]
A low semi die angle (15-30°) is beneficial for material flow and extrusion force during clad composite extrusion.
“Although a low semi die angle (15-30 • ) is beneficial for material flow and extrusion force during clad composite extrusion [5,9], this implies long and high-volume extrusion discards and, therefore, reduced turnout.”
From Influence of Die Surface Topography and Lubrication on the Product Quality during Indirect Extrusion of Copper-Clad Aluminum Rods (2020) · cites this paper as [5]
A semi die angle of 45° was selected for the die configuration because a low semi die angle (15-30°) implies long and high-volume extrusion discards and reduced turnout.
“For a similar reason, a semi die angle of 45 • was selected for the die configuration.Although a low semi die angle (15-30 • ) is beneficial for material flow and extrusion force during clad composite extrusion [5,9], this implies long and high-volume extrusion discards and, therefore, reduced turnout.”
From Influence of Die Surface Topography and Lubrication on the Product Quality during Indirect Extrusion of Copper-Clad Aluminum Rods (2020) · cites this paper as [5]
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Kuhnke, S., Gensch, F., Nitschke, R., Sanabria, V., & Mueller, S. (2020) · Metals · doi:10.3390/met10070888 · Cited by 13 · see citing works
“Although a low semi die angle (15–30°) is beneficial for material flow and extrusion force during clad composite extrusion [5,9], this implies long and high-volume extrusion discards and, therefore, reduced turnout.”
BackgroundNumerical Investigations on Material Flow During Indirect Extrusion of Copper-Clad Aluminum Rods
Kuhnke, S., Sanabria, V., Gensch, F., Nitschke, R., & Mueller, S. (2020) · Frontiers in Materials · doi:10.3389/fmats.2020.00157 · Cited by 11 · see citing works
Lechner, S., Rœmisch, U., Nitschke, R., Gensch, F., & Mueller, S. (2021) · Frontiers in Materials · doi:10.3389/fmats.2021.663306 · Cited by 6 · see citing works
- Authors
- Haghighat, H., & Momeni-Khabisi, H.
- Affiliations
- Razi University (IR)
- Mechanical Engineering Department, Islamic Azad University, Kahnooj branch, Kerman, Iran
- Corresponding author
- Haghighat, H
- ORCID
- Haghighat, H
- Venue
- Australian Journal of Mechanical Engineering
- Publisher
- Informa UK Limited
- Published
- 2014-01
- Volume
- 12
- Issue
- 3
- Pages
- 282-290
- ISSN
- 1448-4846 (ISSN-L)
- 2204-2253
- OpenAlex
- W2001163107
- Cited by
- 3
- References
- 0
- Citations by year
- 2021: 1 · 2020: 2
- FWCI
- 0.00
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Australian Journal of Mechanical Engineering (publishedVersion)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Metal Forming Simulation Techniques
- Physical Sciences › Engineering › Mechanics of Materials › Metallurgy and Material Forming
- Physical Sciences › Engineering › Civil and Structural Engineering › Engineering Applied Research
- Keywords
- backward extrusion, conical punch, upper bound method, extrusion force, friction factor, area reduction, deformation zone
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