Papers by Keyword: AA1100

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Authors: Beong Bok Hwang, G.M. Lee, Y.H. Lee, J.H. Ok, S.H. Kim
Abstract: In the present study, the finite element analysis has been conducted to investigate the deformation characteristics of forward and backward can extrusion process using AA 1100 aluminum alloy tubes in terms of maximum forming load and extruded length ratio in a combined material flow. A commercially available code is used to conduct rigid-plastic FEM simulation. Hollow tubes are selected as initial billets and the punch geometries follow the recommendation of ICFG. Selected design parametrs involved in simulation includes punch nose radius, die corner radius, frictional condition, and punch face angle. The investigation is foucused on the analysis of deformation pattern and its characteristics in a forward tube extrusion combined simultaneously with backward tube extrusion process main in terms of force requirements for this operation according to various punch nose radii and backward tube thickness. The simulation results are summarized in terms of load-stroke relationships for different process parameters such as backward tube thickness, die corner radii, and punch face angle, respectively, and pressure distributions exerted on die, and comparison of die pressure and forming load between combined extrusion and two stage extrusion process in sequencial operation. Extensive analyses are also made to investigate the relationships between process parameters and extruded lengths in both forward and backward directions. It has been concluded from simulation results that a) the combined operation is superior to multi-stage extrusion process in sequential operation in terms of maximum forming load and maximum pressure exerted on die, b) the length of forward extruded tube increases and that of backward extruded tube decreases as the thickness ratio decreases, and c) the forming load is influenced much by the thickness ratio and the other design factors such as die corner radius and punch face angle does not affect much on the force requirement for the combined extrusion process.
Authors: J.H. Ok, Beong Bok Hwang
Abstract: This paper is concerned with the analysis on the surface expansion of AA 2024 and AA 1100 aluminum alloys in backward extrusion process. Due to heavy surface expansion appeared usually in the backward can extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the surface expansion is analyzed especially under various process conditions. The main goal of this study is to investigate the influence of degree of reduction in height, geometries of punch nose, friction and hardening characteristics of different aluminum alloys on the material flow and thus on the surface expansion on the working material. Two different materials are selected for investigation as model materials and they are AA 2024 and AA 1100 aluminum alloys. The geometrical parameters employed in analysis include punch corner radius and punch face angle. The geometry of punch follows basically the recommendation of ICFG and some variations of punch geometry are adopted to obtain quantitative information on the effect of geometrical parameters on material flow. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward can extrusion process under different geometrical, material, and interface conditions. The simulation results are summarized in terms of surface expansion at different reduction in height, deformation patterns including pressure distributions along the interface between workpiece and punch, comparison of surface expansion between two model materials, geometrical and interfacial parametric effects on surface expansion, and load-stroke relationships. It has been concluded from the present study that the geometrical condition of punch is the most significant factor among the parameters employed in this study. It is also known from the simulation results that the difference in surface expansion according to different material properties is not more or less significant.
Authors: Nobuhiro Tsuji, Yoshiaki Ito, H. Nakashima, Fusahito Yoshida, Yoritoshi Minamino
Authors: Dong Hwan Jang, Beong Bok Hwang
Abstract: This paper is concerned with the analysis of plastic deformation of bimetal co-extrusion process. Extrusion is related to large deformation of material and leads to non-homogeneous deformation within work-piece material. The mechanism of plastic deformation during the composite rod extrusion is much more complicated than that in single metal extrusion. Deformation patterns of co-extrusion of two different materials are characterized by several process parameters. In this paper, the analysis is focused to investigate the effect of contact conditions along the interface between two different materials. The rigid-plastic finite element method was applied to the analysis of co-extrusion process. The selected materials are AA 1100 aluminum alloy as hard material and CDA 110 as soft one. This type of material selection was to examine the effect of hard core and soft sleeve and vice versa in terms of deformation pattern. The initial composite billets were prepared by inserting the core material in tight (0.023mm) and weak (0.012mm) interference bonding, respectively. Four different cases of co-extrusion process in terms of material combination and interference bonding were simulated to investigate the effect of material arrangement between core and sleeve, and of bonding on the plastic zones. It is concluded from the simulation results that the plastic zones in this co-extrusion process are not influenced much by the selection of material arrangements or bonding condition between construction materials. However, it was seen from the simulation results that the extrusion ratio of each construction material, i.e. homogeneity of co-extrusion, depends much on the material arrangement and the bonding condition.
Authors: R Padmanaban, V. Muthukumaran, A. Vighnesh
Abstract: Friction stir welding (FSW) has become a potential solid state joining technique with considerable advantages over conventional joining process. Defect-free friction stir welded joints with high joint strength are obtained when optimum process parameters are used. Although a large number of parameters govern the FSW process, the tool rotation speed, Welding speed and tool geometry are key parameters that influence the joint strength. In this work, a statistical model relating process parameters and the tensile strength (TS) of friction stir welded AA1100 joints is build using response surface methodology. The four independent variables are tool rotational speed (TRS), welding speed (WS), shoulder diameter (SD) and pin diameter (PD). Central Composite design is used and Analysis of Variance at 95% confidence level was applied to assess the adequacy of the developed model. Genetic algorithm is used for optimizing the parameters. The optimum process parameter values predicted using the genetic algorithm are as follows. Tool rotation speed: 1001.9 rpm; welding speed: 62 mm/min; shoulder diameter: 17.8 mm and pin diameter: 6.5 mm. The corresponding tensile strength of the joints is 73.1556 MPa
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