Experimental investigation and numerical simulation of large-sized aluminum tube extrusion forming

Abstract

Large-sized aluminum tube has big section effect, aspect ratio and thin thickness, so that the extrusion technology is complex and the large specific pressure is generated in extrusion cavity. The temperature variation and velocity effect is difficult to control. The extrusion forming of large-sized aluminum tube was researched and simulated. Three-dimensional thermo-mechanical coupled finite element model was constructed and appropriate boundary conditions were given out. The results show that large-sized aluminum tube can be formed by isothermal extrusion through controlling the extrusion velocity and founding the relationship between extrusion velocity and extrusion temperature.

Keywords

large-sized aluminum tube / extrusion / numerical simulation

References

[1] KuwabaraT., YoshidaK., NariharaK., TakahashiS.. Anisotropic plastic deformation of extruded aluminum alloy tube under axial forces and internal pressure[J]. International Journal of Plasticity, 2005, 21(1): 101-117

[2] MikaelJ., LarsgunnarN., KjellS.. On constitutive modeling of aluminum alloys for tube hydroforming applications[J]. International Journal of Plasticity, 2005, 21(10): 1041-1058

[3] MichaelK., HerbertB., DavidH., AnjaliK. M., SilvaD.. Enhancing the formability of aluminium components via temperature controlled hydroforming[J]. Journal of Materials Processing Technology, 2005, 167(2/3): 363-370

[4] DinoA., OliveirA., MichaelJ., RassinG., BruceW.. Effect of forming process variables on the crashworthiness of aluminum alloy tubes[J]. International Journal of Impact Engineering, 2006, 32(5): 826-846

[5] KenichiM., MasamithuS., HiroshiK., YangM.. Hydroforming process optimization of aluminum alloy tube using intelligent control technique[J]. International Journal of Machine Tools & Manufacture, 2006, 46(11): 1207-1211

[6] SivaN., VarmaP., AlanR., SachdevA. K.. An analysis of localized necking in aluminium alloy tubes during hydroforming using a continuum damage model[J]. International Journal of Mechanical Sciences, 2007, 49(2): 200-209

[7] LiQ., SmithC. J., HarrisC.. Finite element investigations upon the influence of pocket die design on metal flow in aluminium extrusion[J]. Journal of Materials Processing Technology, 2003, 135(2/3): 189-196

[8] PanditM., KaiserslauternL.. Trends and perspectives concerning temperature measurement and control in aluminium extrusion[J]. Aluminium, 2000, 76(7): 564-573

[9] LiD.-y., ZhouF., ChangQ.-f., PengY.-hong.. Contrast of FEM and FVM in simulation of complex aluminum extrusion[J]. Trans Nonferrous Met Soc China, 2006, 12(S3): 1275-1278

[10] LofJ.. FEM simulation of the aluminium flow in the bearing area for extrusion of thin-walled sections[J]. Journal of Materials Processing Technology, 2001, 114(9): 174-183

[11] LofJ.. FEM simulation of the extrusion of complex thin-walled aluminium sections[J]. Journal of Materials Processing Technology, 2002, 122(7): 344-354

[12] ChungS. W., KimW. J., HigashiK.. The effect of die geometry on the double shear extrusion by parametric FVM simulation[J]. Scripta Materialia, 2004, 51(3): 1117-1122

[13] KobayashiS., OhS. I., AltanT.Metal forming and the finite element method[M], 1989, New York, Oxford University Press: 12-49

[14] SlagterW. J., FlorieC. J. L., VenisA. C. J.. Advances in 3D forging process modeling[J]. Journal of Computational Physics, 1991, 92(4): 82-105

[15] ZhouF., PengY.-h., RuanX.-yu.. Simulation of aluminium material extrusion process with finite element method[J]. Journal of Shanghai Jiaotong University, 2003, 37(2): 149-152