Papers by Author: Luca Tomesani

Abstract: The aim of the present work was the assessment of the impact of deep-rolling and shot-peening performed in the underhead and in the unthreaded shank of two high strength screws (36 NiCrMo and 42 CrMoV) for fatigue life enhancement. The experimental campaign consisted of six combinations, including the non-treated state. The aforementioned treatments were evaluated alone or with shot-peening performed after deep-rolling in the underhead fillet of the screws. Deep rolling was carried out at the optimal rolling force, whereas two shot diameters were considered for shot-peening (Z100 and UFS70). The results have been evaluated in terms of fatigue limits and factor effects have been assessed by marginal mean plots.

Abstract: An experimental campaign on a tubular hollow profile, extruded in industrial environment at two ram speeds, was performed to compare two testing methodologies used for the assessment of the seam welds strength: the cone expansion and the bulge tests. In the former, a cone-shaped punch is driven into the tube causing the expansion till the specimen fracture; in the latter, an internal rubber plug is used to expand the specimen allowing to apply an hydrostatic tensile state. Results and repeatability of the two tests were analyzed in terms of loads and tube radius elongations at fracture; location and morphology of the fracture were also inspected. In each condition, and for both tests, ductile fractures appeared at seam weld location. The bulge test showed a significant reduced data scattering if compared to the cone test and provided more conservative outcomes in terms of elongation at fracture; in addition, it marked more prominently the effect of the increased ram speed that promoted a weld strength decay.

Abstract: The final microstructure of extruded profiles is of great importance for final mechanical properties and, consequentially, the ability to control and predict it is of extreme interest for Academic and Industrial researchers. In the paper a combined model, able to discern recrystallized areas respect to fibrous structures within the same profile, is initially proposed then validated through FEM implementation on an experimental campaign performed by Parson [1]. The model was tested under different die geometries and process conditions and a qualitative comparison with final microstructure obtained in the extrusion of a simple aluminum rod was performed.

Abstract: A bridge die was designed for the simultaneous extrusion of two rectangular profiles and used in a strictly monitored aluminum extrusion process. Experimental investigations aimed at the measurement of the mandrel deflection, the local die temperature, and the pressure inside the welding chamber by means of special measurement equipment. AA6082 alloy was used as extrusion material. The influence of the extrusion speed on the aforementioned objectives is reported. The experiments were repeated at least three times under the same conditions in order to achieve a statistical validation of the acquired data. These data are provided as reference for the 2013 edition of the Extrusion Benchmark.

Abstract: The increasing attention to magnesium alloys in extruded profiles, especially in the transportation industry, is related to their low density associated with good mechanical properties and complete recyclability. This allows to push towards both increasing efficiency and pollution restrictions. However, these advantages are negatively balanced by the production rates drop in relation to dangerous profile temperatures increasing that force to keep low velocities. In this context, a novel porthole die has been purposely designed for magnesium alloys allowing an increasing of the process velocity up to four times with respect to past solutions. The mandrel consisted of three ports made by 120° bridges that created an equal number of seam welds. The extruded tubes, made in ZM21, were 50 mm in diameter and 2 mm in thickness and were tested under different process conditions. In the present work, the quality of the seam welds has been investigated in relation to each process condition by means of the rubber plug testing method that allowed to applied an hydrostatic tensile state.

Abstract: Aim of the work is to investigate different strategies in balancing material flow during direct extrusion through porthole dies. Two AA6082 hollow profiles were simultaneously extruded by a single die with different portholes extrusion ratio, dissimilar welding chambers and different bearing lengths. A strict process control was realized by measuring thermal conditions in the die by means of 6 thermocouples and on the profiles by a self calibrating pyrometer for aluminum alloy applications. Several billets were extruded at different ram speeds (2 to 7 mm/sec) and the effect of die design on surface quality, profile lengths and thermal field was recorded. The profiles were then sectioned and the position of the seam welds in the profiles identified and compared also with the profiles tip.

Abstract: Although the extrusion process is regarded as a continuous process, in practice billets are discretely loaded into the press. The joining of two consecutive billets is guaranteed by the high hydrostatic pressure of the process. Nevertheless, mechanical proprieties of the profile in the welded region are lower than those of the adjacent area thus leading to the discarding of the welded segment. Extension of the segment is mainly affected by the interaction of seam and charge welding phenomena and, nowadays, its prediction is still a tricky task involving rough empirical relations or labour intensive analyses. Aim of this work was to identify the starting and exhausting points of the charge welds evolution inside an industrial multi-profiles die, in order to determine the exact position and the minimal length to be scraped. The extrusion of four AA6060 hollow profiles through a multi-hole die were preliminary monitored in an industrial press by accurate recording of the process loads, temperatures and speeds during the process. The four profiles were sectioned starting from the ‘stop mark’ then grinded and etched in order to investigate the location and the dimension of the zone to be ridded. While the experimental activity is detailed elsewhere, this paper is focused on the finite element modelling of the process. The numerical simulation was performed by means of the Altair HyperXtrude code and predictions compared to experimental data with a particular focus on the computation of the charge evolution. It was found a good agreement both in terms of general trend and prediction of the exhausting points so thus proving the code to be a reliable tool for an accurate determination of the scraps.

Abstract: Tools are exposed to severe working conditions during the hot extrusion process. In particular, dies and mandrels can be subjected to an excessive amount of deformation as a result of the developed high cyclic loads and temperatures. In this scenario, a physical experiment reproducing the thermo-mechanical conditions of a mandrel in a porthole die was performed with the Gleeble machine on the AISI H11 tool steel with the aim to investigate the mechanisms that influence the die deformation. The design of experiment consisted of 4 levels of temperature, 3 levels of stress and 3 types of load, i.e. pure creep, pure fatigue and creep-fatigue. In all the testing conditions, a comparable pattern of the mandrel displacement-time curve was found reproducing the 3 stages of softening typical of the strain evolution in a standard creep test but with a marked primary phase. Thus, with the aim to identify an easy-applicable equation to estimate the die deformation, the time hardening creep law was chosen. Coefficients of the time-hardening law were optimized, for each testing condition, on the basis of experimental data starting from values for similar alloys taken from the literature. Results in terms of mandrel displacement were then compared to experimental data for the creep-fatigue condition at different stress and temperature levels. The values found were validated against additional experimental data performed with different specimen geometries. A good average agreement was found between experimental and numerical results. The developed procedure was then applied to an industrial die.

Abstract: In the paper, a die for the production of a complex hollow profile made by AA6060 alloy on an industrial 2500 ton press has been manufactured and tested under strict monitored conditions. In particular 5 thermocouples were placed in proximity of interesting positions inside the die: 3 next to the bearings and two near the welding chambers. A self-calibrated pyrometer was used for the temperature monitoring of profile. Press loads, ram speeds and container temperatures were continuously recorded directly from the press system. Six billets were initially extruded in order to reach a steady state condition being the last three used as industrial benchmark for the 2011 edition of the ICEB conference. Then the nitrogen was completely and partially opened and the evolution of the temperature in the die and in the profile recorded together with the process load. The effect on bearing temperature was extreme, in particular in proximity of nitrogen inlet, while almost no change in welding chamber thermocouples and in the process load was revealed.

Abstract: In the paper experimental investigations aimed at allowing a detailed and accurate comparison of different FEM codes were presented and discussed. Two hollow profiles within the same die were characterized by different thicknesses within the profile, two welding chambers and critical tongues (one fully supported and one partially supported). The material flow balance was performed by means of feeder size and position on a profile and by means of bearings on the other one. Accurate monitoring of process parameters was carried out by using a self-calibrating pyrometer for profile temperature, six thermocouples for die thermal monitoring, a laser velocitymeter for profile speed and two laser sensors for die deflection on critical tongues. AA6082 alloy was used as deforming material, while H-11 hot-work tool steel was selected for the die material. The experiments were repeated at least three times under the same conditions in order to provide a nearly steady state statistical distribution of the acquired data. These are used as a reference for the 2011 edition of the extrusion benchmark.