Experimental and Numerical Analysis of Material Flow in Porthole Die Extrusion

Abstract:

The design of porthole dies for aluminum extrusion processes is very complex. For the accurate design, fundamental knowledge about material flow is of major importance. To gain these information, numerical methods are increasingly utilized. The accuracy of the simulation results depends mainly on the precision of the used boundary conditions in the model. Therefore, visioplastic analyses of the material flow inside a porthole die are presented in this paper. A special modular tool concept was developed to prepare and visualize the material flow inside the process. The results of the experimental analysis were used for the verification of numerical results which were calculated with the commercial software codes Deform3D and HyperXtrude.

• Periodical: Key Engineering Materials (Volume 491)
• Pages: 97-104
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.491.97
• Online since: September 2011
• Authors: Thomas Kloppenborg, M. Schwane, Nooman Ben Khalifa, A. Erman Tekkaya, Alexander Brosius
• Keywords: Extrusion, Material Flow, Porthole Die, Visioplastic Analysis

References

[1] L. Donati, L. Tomesani, M. Schikkora, N. Ben Khalifa and A.E. Tekkaya: Friction model selection in FEM simulations of aluminum extrusion, Int. j. Surface Science and Engineering, Vol. 4, No. 1 (2010).

DOI: 10.1504/ijsurfse.2010.029627

[2] H. S. Valberg: Applied metal forming: including FEM analysis, Cambridge University Press (2010).

[3] C. P. Hinesley and H. Conrad: Effects of Temperature and Ram Speed on the Flow Pattern in Axisymmetric Extrusions of 2024 Al Alloy, Materials Science and Engineering, 12, pp.47-58 (1973).

DOI: 10.1016/0025-5416(73)90071-2

[4] J.X. Xie, T. Murakami, K. Ikeda, H. Takahashi: Experimental simulation of metal flow in porthole-die extrusion, Journal of Materials Processing Technology, 49 pp.1-11 (1995).

DOI: 10.1016/0924-0136(94)01324-t

[5] H. S. Valberg: Experimental techniques to characterize large plastic deformations in unlubricated hot aluminum extrusion, Key Engineering Materials Vol. 367, pp.17-24 (2008).

DOI: 10.4028/www.scientific.net/kem.367.17

[6] H. Valberg: Metal flow in the direct axisymmetric extrusion of aluminum, Journal of Materials Processing Technology, 31, pp.39-55 (1992).

DOI: 10.1016/0924-0136(92)90005-d

[7] Y. A. Khan and H. S. Valberg: Studies of Porthole Extrusion through Die with Different Sizes of Portholes, The 14th International ESAFORM Conference on Material Forming, Conf. Proc. 1353, pp.473-478 (2011).

DOI: 10.1063/1.3589560

[8] Y. -T. Kim, K. Ikeda, and T. Murakami: Metal flow in porthole die extrusion of aluminum, Journal of Materials Processing Technology, 121, pp.107-115 (2002).

DOI: 10.1016/s0924-0136(01)01215-8

[9] T. Kloppenborg, N. Ben Khalifa, A. E. Tekkaya, Accurate Welding Line Prediction in Extrusion Processes, In: Trans Tech Publications, Key Engineering Materials, ISSN 1013-9826, Volume 424, pp.87-95 (2010).

DOI: 10.4028/www.scientific.net/kem.424.87