Extrusion is a manufacturing process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. A brief and concise review of the contributions made by the previous researchers in the area of extrusion process has been presented. Steel material and aluminium alloys are mostly used by researchers as die and billet material in extrusion process. FEM modeling of extrusion process is carried out by employing axisymmetric conditions in most cases. Meshing of the work piece is generally done by using axisymmetric quadrilateral elements. Experimental set-up and tools utilized in formation of extrusion process are presented and discussed. FEM results are presented in terms of variation of punch stroke, punch force.
Experimental Investigation and Analysis of Extrusion of Lead from Round Secti...IOSR Journals
Abstract : An experimental investigation has been done on the changes of die angle, area reduction in dies,
loading rate on the final extruded products, extrusion pressures of lead of circular cross sections of different
length. The proposed method is successfully adapted to the extrusion of the equilateral triangular section from
round billet through converging dies of different area reductions. Computation of extrusion pressure at various
area reductions and finite element analysis of different parameters (stress, strain, velocity) both in dry and wet
condition.
Keywords - Converging dies, Extrusion of the equilateral triangular section, Extrusion Pressure
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
Investigation of Extrusion of Lead experimentally from Round section through ...inventy
ABSTRACT :The changes of die angle, area reduction in dies, loading rate on the final extruded products, extrusion pressures of lead of circular cross sections has been investigated experimentally. The proposed method is successfully adapted to the forward extrusion of the equilateral triangular section from round billet through converging dies of different area reductions. Computation of extrusion pressure at various area reductions and calculations of different parameters (stress, strain etc.) in wet condition.
Keywords - Extrusion of Triangular section, Converging Dies at different area reductions, Friction Factor, Extrusion Pressure
Parametric Analysis of Mild Steel Specimens Using Roller Burnishing ProcessIRJESJOURNAL
ABSTRACT:- Burnishing, a cold working process, is a very simple and effective method of improving surface properties, which can easily be carried out using existing machines, such as lathe. With changing trends in manufacturing industry, special attention is given on surface finish along with dimensional accuracy and tight geometrical tolerances. Burnishing comes in mind as one of popular finishing process because it is completely chip-less as compared to other finishing processes such as grinding, honing etc. The purpose of the research was to demonstrate burnishing process on ferrous metals namely mild steel alloy. Parametric analysis was done using speed and feed rate as input parameters and surface roughness & surface micro hardness as response variables. Burnishing was performed using Hindustan machine tools (HMT) power lathe (NH 26 model)
The Comparison of Properties of Tinplates during Uniaxial and Biaxial Stresstheijes
The majority of thin steel sheets is used to make of food covers, cans, capsules and other products, which are produced by metal forming. Concerning considerable changes in production of tinplates and still higher requests on their properties there is requirement to use such methods on their evaluation, which are able to determine especially mechanical and plastic properties of sheets quickly and with the low costs. Following of present know-how there were developed new testing methods, which correspond more to steel sheets stress during technological treatment (concerning their stress-strain state). In the contribution we deal with the comparison of properties of tinplates during uniaxial tensile test and biaxial tensile test.
Probabilistic approach to study the hydroformed sheetIJERA Editor
Under the leadership of the Kyoto agreements on reducing emissions of greenhouse gases, the automotive sector was forced to review its methods and production technologies in order to meet the new environmental standards. In fuel consumption reduction is an immediate way to reduce the emission of polluting gases. In this paper, the study of the formability of sheet submitted to the hydroforming process is proposed. The numerical results are given to validate the proposed approach. To show the influence of uncertainties in the study process, we take some characteristics of the material as random and the probabilistic approach is done. The finding results are showing the effectiveness of the proposed approach.
Experimental Investigation and Analysis of Extrusion of Lead from Round Secti...IOSR Journals
Abstract : An experimental investigation has been done on the changes of die angle, area reduction in dies,
loading rate on the final extruded products, extrusion pressures of lead of circular cross sections of different
length. The proposed method is successfully adapted to the extrusion of the equilateral triangular section from
round billet through converging dies of different area reductions. Computation of extrusion pressure at various
area reductions and finite element analysis of different parameters (stress, strain, velocity) both in dry and wet
condition.
Keywords - Converging dies, Extrusion of the equilateral triangular section, Extrusion Pressure
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
Investigation of Extrusion of Lead experimentally from Round section through ...inventy
ABSTRACT :The changes of die angle, area reduction in dies, loading rate on the final extruded products, extrusion pressures of lead of circular cross sections has been investigated experimentally. The proposed method is successfully adapted to the forward extrusion of the equilateral triangular section from round billet through converging dies of different area reductions. Computation of extrusion pressure at various area reductions and calculations of different parameters (stress, strain etc.) in wet condition.
Keywords - Extrusion of Triangular section, Converging Dies at different area reductions, Friction Factor, Extrusion Pressure
Parametric Analysis of Mild Steel Specimens Using Roller Burnishing ProcessIRJESJOURNAL
ABSTRACT:- Burnishing, a cold working process, is a very simple and effective method of improving surface properties, which can easily be carried out using existing machines, such as lathe. With changing trends in manufacturing industry, special attention is given on surface finish along with dimensional accuracy and tight geometrical tolerances. Burnishing comes in mind as one of popular finishing process because it is completely chip-less as compared to other finishing processes such as grinding, honing etc. The purpose of the research was to demonstrate burnishing process on ferrous metals namely mild steel alloy. Parametric analysis was done using speed and feed rate as input parameters and surface roughness & surface micro hardness as response variables. Burnishing was performed using Hindustan machine tools (HMT) power lathe (NH 26 model)
The Comparison of Properties of Tinplates during Uniaxial and Biaxial Stresstheijes
The majority of thin steel sheets is used to make of food covers, cans, capsules and other products, which are produced by metal forming. Concerning considerable changes in production of tinplates and still higher requests on their properties there is requirement to use such methods on their evaluation, which are able to determine especially mechanical and plastic properties of sheets quickly and with the low costs. Following of present know-how there were developed new testing methods, which correspond more to steel sheets stress during technological treatment (concerning their stress-strain state). In the contribution we deal with the comparison of properties of tinplates during uniaxial tensile test and biaxial tensile test.
Probabilistic approach to study the hydroformed sheetIJERA Editor
Under the leadership of the Kyoto agreements on reducing emissions of greenhouse gases, the automotive sector was forced to review its methods and production technologies in order to meet the new environmental standards. In fuel consumption reduction is an immediate way to reduce the emission of polluting gases. In this paper, the study of the formability of sheet submitted to the hydroforming process is proposed. The numerical results are given to validate the proposed approach. To show the influence of uncertainties in the study process, we take some characteristics of the material as random and the probabilistic approach is done. The finding results are showing the effectiveness of the proposed approach.
Simulation and experimental studies for lateral extrusion of square and penta...eSAT Journals
Abstract Recently, in different industries a surging trend has been observed in the demand of integral parts instead of assembled parts due to their increased strength. The components from lateral extrusion process are suitable for this purpose. Variations in load and flow direction of metal are greatly affected by the extruded geometry in this process. Keeping in view the above factors as an objective, an experimental die-punch set-up for lateral extrusion is designed and the process is simulated using finite element method both for estimation of load requirement and metal flow patterns. Experimental studies have been carried out to find the extrusion load and the direction of metal flow at different die geometry, taking lead as the billet material. The predictions both in extrusion load and the deformed configuration are in good agreement with the experiment qualitatively under different geometry conditions. Progressive flow of metal at different die geometry has also been studied. Index Terms: Die-punch, Finite element analysis, Forming load, Lateral extrusion, Metal flow pattern
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Extrusion can be defined as the process of subjecting a material to compression so that it is forced to
flow through an opening of a die and takes the shape of the hole. Multi-hole extrusion is the process of
extruding the products through a die having more than one hole. Multi-hole extrusion increases the production
rate and reduces the cost of production. In this study the ram force has calculated experimentally for single hole
and multi-hole extrusion. The comparison of ram forces between the single hole and multi-hole extrusion
provides the inverse relation between the numbers of holes in a die and ram force. The experimental lengths of
the extruded products through the various holes of multi-hole die are different. It indicates that the flow pattern
is dependent on the material behavior. The micro-hardness test has done for the extruded products of lead
through multi-hole die. It is observed that the hardness of the extruded lead products from the central hole is
found to be more than that of the products extruded from other holes. The study suggests that multi-hole
extrusion can be used for obtaining the extruded products of lead with varying hardness. The micro-structure
study has done for the lead material before and after extrusion. It is observed that the size of grains of lead
material after extrusion is smaller than the original lead.
Effects of Cutting Tool Parameters on Surface Roughnessirjes
This paper presents of the influence on surface roughness of Co28Cr6Mo medical alloy machined
on a CNC lathe based on cutting parameters (rotational speed, feed rate, depth of cut and nose radius).The
influences of cutting parameters have been presented in graphical form for understanding. To achieve the
minimum surface roughness, the optimum values obtained for rpm, feed rate, depth of cut and nose radius were
respectively, 318 rpm, 0,1 mm/rev, 0,7 mm and 0,8 mm. Maximum surface roughness has been revealed the
values obtained for rpm, feed rate, depth of cut and nose radius were respectively, 318 rpm, 0,25 mm/rev, 0,9
mm and 0,4 mm.
Finite Element Analysis of Copper Deformed By Conventional Forward ExtrusionIOSR Journals
Equal channel angular extrusion (ecae) is a novel deformation process capable of imparting a large
amount of plastic strain to bulk material through the application of uniform simple shear. Ecae die geometry,
material properties and process conditions influence the shear deformation behavior during extrusion that in
turn governs the microstructure and mechanical properties of the extruded materials. Finite element analysis,
the most appropriate technique was used to analyze the deformation behavior of extruded materials without
neglecting important and realistic factors like strain hardening behavior of the material, frictional conditions
and speed of the process. In this study the deformation behavior of material, dead zone/corner gap formation
and strain homogeneity in friction and frictionless condition achieved in the samples during ecae were studied
by using commercial finite element code abaqus/cae6.11-3. The influence of channel angles, strain hardening
behavior of material and friction between the billet and die was considered for simulations. Results showed that
the optimal strain homogeneity in the sample with lower dead zone formation, without involving any detrimental
effects, can be achieved with channel angle of 90 degrees and outer corner angle of 10 degrees for pure copper
Regression analysis of shot peening process for performance characteristics o...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Computer Science
Active and Programmable Networks
Active safety systems
Ad Hoc & Sensor Network
Ad hoc networks for pervasive communications
Adaptive, autonomic and context-aware computing
Advance Computing technology and their application
Advanced Computing Architectures and New Programming Models
Advanced control and measurement
Aeronautical Engineering,
Agent-based middleware
Alert applications
Automotive, marine and aero-space control and all other control applications
Autonomic and self-managing middleware
Autonomous vehicle
Biochemistry
Bioinformatics
BioTechnology(Chemistry, Mathematics, Statistics, Geology)
Broadband and intelligent networks
Broadband wireless technologies
CAD/CAM/CAT/CIM
Call admission and flow/congestion control
Capacity planning and dimensioning
Changing Access to Patient Information
Channel capacity modelling and analysis
Civil Engineering,
Cloud Computing and Applications
Collaborative applications
Communication application
Communication architectures for pervasive computing
Communication systems
Computational intelligence
Computer and microprocessor-based control
Computer Architecture and Embedded Systems
Computer Business
Computer Sciences and Applications
Computer Vision
Computer-based information systems in health care
Computing Ethics
Computing Practices & Applications
Congestion and/or Flow Control
Content Distribution
Context-awareness and middleware
Creativity in Internet management and retailing
Cross-layer design and Physical layer based issue
Cryptography
Data Base Management
Data fusion
Data Mining
Data retrieval
Data Storage Management
Decision analysis methods
Decision making
Digital Economy and Digital Divide
Digital signal processing theory
Distributed Sensor Networks
Drives automation
Drug Design,
Drug Development
DSP implementation
E-Business
E-Commerce
E-Government
Electronic transceiver device for Retail Marketing Industries
Electronics Engineering,
Embeded Computer System
Emerging advances in business and its applications
Emerging signal processing areas
Enabling technologies for pervasive systems
Energy-efficient and green pervasive computing
Environmental Engineering,
Estimation and identification techniques
Evaluation techniques for middleware solutions
Event-based, publish/subscribe, and message-oriented middleware
Evolutionary computing and intelligent systems
Expert approaches
Facilities planning and management
Flexible manufacturing systems
Formal methods and tools for designing
Fuzzy algorithms
Fuzzy logics
GPS and location-based app
COMPARATIVE STUDY OF THE EFFECT OF DWELLING THE PUNCH AT THE BDC VS WITHOUT D...IAEME Publication
Since past many years the manufacturing industry has made use of the conventional presses for sheet metal forming. Many advantages as well as the limitations of the conventional presses are known by now. The servo presses came into existence many years ago but are now starting to gain popularity because of its flexible slide motion programming and other significant characteristics which are unique to the servo presses. Majority of the components in various industries are made by deep drawing sheet metal process. So these growing demands need new sheet metal forming techniques which improve the quality, increase production and save time. To be able to dwell at the BDC for some time is a unique characteristic of the servo press compared to the conventional press.
Modeling and finite element analysis for a casting defect in thin wall struct...Dr.Vikas Deulgaonkar
The casting of pump impeller blades is a difficult operation due to its thin wall structure. In the casting process for thin wall impeller structure, the prediction of shrinkage defect is a one of the important issue and failure of such thin wall structure is a commonly encountered problem. The non-uniform heat transfer rate is the main cause of such failure. The uniformity of heat transfer rate may enhance by placing the runner at appropriate position and riser based on the geometrical attributes. The flow of liquid metal and its solidification has time based temperature variation, shrinkages and porosity distributions in such structures. An attempt is made for the analysis of optimization in the placement of runner and riser through this experimentation. The experiment contains the analysis of finite element simulation of fluid flow and solidification of metal execution at various temperatures, prediction of shrinkages based on the geometry of the casting and flow curvature and porosity distribution. This work also focuses on the prediction of casting defects in aluminum thin wall pump impeller structure using commercially available software (ANSYS-FLUENT). The experimental validation of the simulation result is also done to confirm the same.
Perforated Sheet Analysis Using Equivalent Modelingspawar4
This presentation reviews various methods used for analyzing perforates sheets using equivalent modeling with FEM. It can be used for both sttaic and dynamic analysis.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Effect of process parameters on surface roughness during grinding of hot work...IJMER
The major demands in machining of parts are closely controlling both geometrical accuracy
and dimensional of engineering component made up of difficult to shape material is increasing
continuously. Surface roughness is the important output responses in the production with respect to
quality and quantity respectively. The abrasive machining grinding process is mostly used to attain the
closer tolerances with better surface finish. In this work the AISI H11 hot work steel was used to
investigate the role of different working environments (dry , wet cooling and compressed gas) and
process parameters ( feed rate, depth of cut and wheel speed) on surface roughness. It was observed
that under wet cooling environment, decrease in feed rate, depth of cut and increase in wheel speed
resulted in significant increase in surface quality
The Effect of Direct- and Cross-Rolling on Mechanical Properties and Microstr...Kaveh Rahimi Mamaghani
Severely deformed commercial pure aluminum sheets by constrained groove pressing are direct and crossrolled.
The grain size evolution and dislocation density during rolling are studied using Williamson-Hall
analysis on x-ray diffraction patterns of the deformed samples. These results and optical microscopy
observations show that subsequent direct or cross-rolling of constrained groove pressed aluminum can
produce elongated fine grains. The minimum crystallite size is achieved after cross-rolling of constrained
groove pressed samples. By direct-rolling or cross-rolling of annealed sheet, the maximum intensity in x-ray
diffraction patterns remains on (200) like annealed aluminum but direct-rolling or cross-rolling of constrained
groove pressed sheets changes the maximum intensity from (111) for constrained groove pressed
sheets to (220). Also, mechanical properties are studied using tensile test and hardness measurement. The
results show that cross-rolling on constrained groove pressed samples is more effective than direct-rolling in
mechanical properties improvement.
Optimization of design parameters for V-bending process using response surfac...217Saiteja
Sheet metal forming is one of the widely used manufacturing process. V- bending is an example of sheet metal forming process. This presentation deals with the optimisation of process parameters for V-bending process using Response Surface Optimization technique
Simulation and experimental studies for lateral extrusion of square and penta...eSAT Journals
Abstract Recently, in different industries a surging trend has been observed in the demand of integral parts instead of assembled parts due to their increased strength. The components from lateral extrusion process are suitable for this purpose. Variations in load and flow direction of metal are greatly affected by the extruded geometry in this process. Keeping in view the above factors as an objective, an experimental die-punch set-up for lateral extrusion is designed and the process is simulated using finite element method both for estimation of load requirement and metal flow patterns. Experimental studies have been carried out to find the extrusion load and the direction of metal flow at different die geometry, taking lead as the billet material. The predictions both in extrusion load and the deformed configuration are in good agreement with the experiment qualitatively under different geometry conditions. Progressive flow of metal at different die geometry has also been studied. Index Terms: Die-punch, Finite element analysis, Forming load, Lateral extrusion, Metal flow pattern
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Extrusion can be defined as the process of subjecting a material to compression so that it is forced to
flow through an opening of a die and takes the shape of the hole. Multi-hole extrusion is the process of
extruding the products through a die having more than one hole. Multi-hole extrusion increases the production
rate and reduces the cost of production. In this study the ram force has calculated experimentally for single hole
and multi-hole extrusion. The comparison of ram forces between the single hole and multi-hole extrusion
provides the inverse relation between the numbers of holes in a die and ram force. The experimental lengths of
the extruded products through the various holes of multi-hole die are different. It indicates that the flow pattern
is dependent on the material behavior. The micro-hardness test has done for the extruded products of lead
through multi-hole die. It is observed that the hardness of the extruded lead products from the central hole is
found to be more than that of the products extruded from other holes. The study suggests that multi-hole
extrusion can be used for obtaining the extruded products of lead with varying hardness. The micro-structure
study has done for the lead material before and after extrusion. It is observed that the size of grains of lead
material after extrusion is smaller than the original lead.
Effects of Cutting Tool Parameters on Surface Roughnessirjes
This paper presents of the influence on surface roughness of Co28Cr6Mo medical alloy machined
on a CNC lathe based on cutting parameters (rotational speed, feed rate, depth of cut and nose radius).The
influences of cutting parameters have been presented in graphical form for understanding. To achieve the
minimum surface roughness, the optimum values obtained for rpm, feed rate, depth of cut and nose radius were
respectively, 318 rpm, 0,1 mm/rev, 0,7 mm and 0,8 mm. Maximum surface roughness has been revealed the
values obtained for rpm, feed rate, depth of cut and nose radius were respectively, 318 rpm, 0,25 mm/rev, 0,9
mm and 0,4 mm.
Finite Element Analysis of Copper Deformed By Conventional Forward ExtrusionIOSR Journals
Equal channel angular extrusion (ecae) is a novel deformation process capable of imparting a large
amount of plastic strain to bulk material through the application of uniform simple shear. Ecae die geometry,
material properties and process conditions influence the shear deformation behavior during extrusion that in
turn governs the microstructure and mechanical properties of the extruded materials. Finite element analysis,
the most appropriate technique was used to analyze the deformation behavior of extruded materials without
neglecting important and realistic factors like strain hardening behavior of the material, frictional conditions
and speed of the process. In this study the deformation behavior of material, dead zone/corner gap formation
and strain homogeneity in friction and frictionless condition achieved in the samples during ecae were studied
by using commercial finite element code abaqus/cae6.11-3. The influence of channel angles, strain hardening
behavior of material and friction between the billet and die was considered for simulations. Results showed that
the optimal strain homogeneity in the sample with lower dead zone formation, without involving any detrimental
effects, can be achieved with channel angle of 90 degrees and outer corner angle of 10 degrees for pure copper
Regression analysis of shot peening process for performance characteristics o...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Computer Science
Active and Programmable Networks
Active safety systems
Ad Hoc & Sensor Network
Ad hoc networks for pervasive communications
Adaptive, autonomic and context-aware computing
Advance Computing technology and their application
Advanced Computing Architectures and New Programming Models
Advanced control and measurement
Aeronautical Engineering,
Agent-based middleware
Alert applications
Automotive, marine and aero-space control and all other control applications
Autonomic and self-managing middleware
Autonomous vehicle
Biochemistry
Bioinformatics
BioTechnology(Chemistry, Mathematics, Statistics, Geology)
Broadband and intelligent networks
Broadband wireless technologies
CAD/CAM/CAT/CIM
Call admission and flow/congestion control
Capacity planning and dimensioning
Changing Access to Patient Information
Channel capacity modelling and analysis
Civil Engineering,
Cloud Computing and Applications
Collaborative applications
Communication application
Communication architectures for pervasive computing
Communication systems
Computational intelligence
Computer and microprocessor-based control
Computer Architecture and Embedded Systems
Computer Business
Computer Sciences and Applications
Computer Vision
Computer-based information systems in health care
Computing Ethics
Computing Practices & Applications
Congestion and/or Flow Control
Content Distribution
Context-awareness and middleware
Creativity in Internet management and retailing
Cross-layer design and Physical layer based issue
Cryptography
Data Base Management
Data fusion
Data Mining
Data retrieval
Data Storage Management
Decision analysis methods
Decision making
Digital Economy and Digital Divide
Digital signal processing theory
Distributed Sensor Networks
Drives automation
Drug Design,
Drug Development
DSP implementation
E-Business
E-Commerce
E-Government
Electronic transceiver device for Retail Marketing Industries
Electronics Engineering,
Embeded Computer System
Emerging advances in business and its applications
Emerging signal processing areas
Enabling technologies for pervasive systems
Energy-efficient and green pervasive computing
Environmental Engineering,
Estimation and identification techniques
Evaluation techniques for middleware solutions
Event-based, publish/subscribe, and message-oriented middleware
Evolutionary computing and intelligent systems
Expert approaches
Facilities planning and management
Flexible manufacturing systems
Formal methods and tools for designing
Fuzzy algorithms
Fuzzy logics
GPS and location-based app
COMPARATIVE STUDY OF THE EFFECT OF DWELLING THE PUNCH AT THE BDC VS WITHOUT D...IAEME Publication
Since past many years the manufacturing industry has made use of the conventional presses for sheet metal forming. Many advantages as well as the limitations of the conventional presses are known by now. The servo presses came into existence many years ago but are now starting to gain popularity because of its flexible slide motion programming and other significant characteristics which are unique to the servo presses. Majority of the components in various industries are made by deep drawing sheet metal process. So these growing demands need new sheet metal forming techniques which improve the quality, increase production and save time. To be able to dwell at the BDC for some time is a unique characteristic of the servo press compared to the conventional press.
Modeling and finite element analysis for a casting defect in thin wall struct...Dr.Vikas Deulgaonkar
The casting of pump impeller blades is a difficult operation due to its thin wall structure. In the casting process for thin wall impeller structure, the prediction of shrinkage defect is a one of the important issue and failure of such thin wall structure is a commonly encountered problem. The non-uniform heat transfer rate is the main cause of such failure. The uniformity of heat transfer rate may enhance by placing the runner at appropriate position and riser based on the geometrical attributes. The flow of liquid metal and its solidification has time based temperature variation, shrinkages and porosity distributions in such structures. An attempt is made for the analysis of optimization in the placement of runner and riser through this experimentation. The experiment contains the analysis of finite element simulation of fluid flow and solidification of metal execution at various temperatures, prediction of shrinkages based on the geometry of the casting and flow curvature and porosity distribution. This work also focuses on the prediction of casting defects in aluminum thin wall pump impeller structure using commercially available software (ANSYS-FLUENT). The experimental validation of the simulation result is also done to confirm the same.
Perforated Sheet Analysis Using Equivalent Modelingspawar4
This presentation reviews various methods used for analyzing perforates sheets using equivalent modeling with FEM. It can be used for both sttaic and dynamic analysis.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Effect of process parameters on surface roughness during grinding of hot work...IJMER
The major demands in machining of parts are closely controlling both geometrical accuracy
and dimensional of engineering component made up of difficult to shape material is increasing
continuously. Surface roughness is the important output responses in the production with respect to
quality and quantity respectively. The abrasive machining grinding process is mostly used to attain the
closer tolerances with better surface finish. In this work the AISI H11 hot work steel was used to
investigate the role of different working environments (dry , wet cooling and compressed gas) and
process parameters ( feed rate, depth of cut and wheel speed) on surface roughness. It was observed
that under wet cooling environment, decrease in feed rate, depth of cut and increase in wheel speed
resulted in significant increase in surface quality
The Effect of Direct- and Cross-Rolling on Mechanical Properties and Microstr...Kaveh Rahimi Mamaghani
Severely deformed commercial pure aluminum sheets by constrained groove pressing are direct and crossrolled.
The grain size evolution and dislocation density during rolling are studied using Williamson-Hall
analysis on x-ray diffraction patterns of the deformed samples. These results and optical microscopy
observations show that subsequent direct or cross-rolling of constrained groove pressed aluminum can
produce elongated fine grains. The minimum crystallite size is achieved after cross-rolling of constrained
groove pressed samples. By direct-rolling or cross-rolling of annealed sheet, the maximum intensity in x-ray
diffraction patterns remains on (200) like annealed aluminum but direct-rolling or cross-rolling of constrained
groove pressed sheets changes the maximum intensity from (111) for constrained groove pressed
sheets to (220). Also, mechanical properties are studied using tensile test and hardness measurement. The
results show that cross-rolling on constrained groove pressed samples is more effective than direct-rolling in
mechanical properties improvement.
Optimization of design parameters for V-bending process using response surfac...217Saiteja
Sheet metal forming is one of the widely used manufacturing process. V- bending is an example of sheet metal forming process. This presentation deals with the optimisation of process parameters for V-bending process using Response Surface Optimization technique
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
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A study on metal extrusion process
1. International Journal of LNCT, Vol 2(6)
ISSN (Online): 2456-9895
124
A study on metal extrusion process
Rahul Ranjan Yadav1
, Yogesh Dewang2
and Jitendra Raghuvanshi2
M.tech scholar, Department of Mechanical Engineering, LNCT Bhopal, India1
Assistant Professor, Department of Mechanical Engineering, LNCT Bhopal, India2
Abstract
Extrusion is a manufacturing process used to create
objects of a fixed cross-sectional profile. A material is
pushed through a die of the desired cross-section. A brief
and concise review of the contributions made by the
previous researchers in the area of extrusion process has
been presented. Steel material and aluminium alloys are
mostly used by researchers as die and billet material in
extrusion process. FEM modeling of extrusion process is
carried out by employing axisymmetric conditions in most
cases. Meshing of the work piece is generally done by
using axisymmetric quadrilateral elements. Experimental
set-up and tools utilized in formation of extrusion process
are presented and discussed. FEM results are presented
in terms of variation of punch stroke, punch force.
Keywords
Tube extrusion process, Finite element simulation, Mesh
adaptivity, Thermo mechanical coupled extrusion.
1.Introduction
Extrusion is metal forming process which is widely
used in industry and daily life equipment . It is
another kind of manufacturing process which
involves shearing and compression. Practical
application of extrusion includes railing for sliding
doors, tubing having various cross sections, structural
and architectural shapes, and door and window
frames. Extruded products can be cut into desired
lengths, which then become discrete parts such as
brackets, gears and coat hangers. It is a process in
which required product can be formed are formed by
using round die or it may various shapes. A round
billet is placed in a chamber and force through a die
opening by hydraulically driven ram or pressing or
pressing stem. This process usually comprises of
axisymmetric die.
The die angle, reduction in cross-section, Extrusion
speed, billet temperature and lubrication all affect the
extrusion pressure. Extrusion is generally classified
into four types. They are: Direct extrusion, indirect
extrusion, impact extrusionand hydrostatic extrusion.
In direct extrusion a solid ram drives the entire billet
to and through a stationary die and must provided
additional power to overcome the frictional power to
overcome the frictional resistance between the
surface of the moving billet and confining chamber.
Figure 1 Direct extrusion [29]
Figure 2 Indirect extrusion [29]
In indirect extrusion process a hollow ram drives the
die back through a stationary, confined billet. Since
no relative motion, friction between the billet and
chamber is eliminated and the required force is lower.
In impact extrusion process the extruded part are
stripped by the use of stripper plate, because they
tend to sticks to the punch.
Figure 3 Hydrostatics Extrusion [30]
2. International Journal of LNCT, Vol 2(6)
125
In hydrostatics extrusion high pressure fluid applies
the force to the workpiece through a die. Billet-
chamber friction is eliminated, and the pressurised
fluid acts as a lubricant between the billet and the die.
In extrusion mesh distortion is the major problem of
FE simulation. In this study we focused on the area of
mesh adaptivity and thermo mechanical modelling of
the forming process. In past, various researchers
contributed in the area of metal extrusion process.
Subramanian and, Palaniradja [1] investigated by
simulating tension and compression by using
different extrusion textures, they found the
differences of mechanical properties between center
and side areas of the extruded bar. Hojda et al. [2]
used Abaqus/Standard for a 3D Finite Element
Method is presented that is capable of simulating the
highly nonlinear hybrid forward extrusion process
(thermomechanical and electric field) incorporating a
remeshing routine, this model is extended to couple a
strain based damage with electrical resistivity Ab
Rahim et al. [3] investigated the trends and the
concept of emerging to identify the recyclability
contents of the product for recycling aluminum chips
by the hot extrusion process. Zhou et al. [4] used an
analytical model for predicting the shapes of
rectangular bars with variable curvatures along their
lengths through a novel forming method, differential
velocity sideways extrusion (DVSE) has been
developed on the basis of the upper bound method.
Joun et al. [5] used dynamic material modeling
(DMM) for selection the processing parameter.
Akhgar et al. [6] investigated hot extrusion of
AA6061–5% SiCp composite to determine the
composite thermo-mechanical behavior during
deformation and the mechanical proper- ties of
extruded composite. Pourbahari et al. [7] investigated
on the grain refinement by the dynamic
recrystallisation (DRX). Tahmasbi et al. [8] used
Friction stir extrusion (FSE) process in which a
sample is produced through the heat generated by the
friction between die and materials, and the extrusion
pressure.Yu and Zhao [9] investigated on the Fine
nano structures of bonding interfaces of weld seams
formed by porthole die extrusion in the absence/
presence of a gas-pocket behind the bridge of the
extrusion die to understand the underlying interfacial
bonding mechanisms. Sahu et al. [10] investigates the
multi-hole extrusion process. Forward, backward and
forward-backward multi-hole extrusions have been
carried out to determine the extrusion load and
variation of extruded product lengths. Wang and
Feng. [11] they were carried out experimental and
numerical simulation to demonstrate that extrusion-
forging process can be used to create such micro
scale surface features. Chen et al. [12] hot extrusion
experiments of AZ91 alloy were carried out at
various ram velocities of 0.1, 0.5 and 1.0 mm/ s.
They investigated the dead metal zone, shearing
zone, inflowing zone and slight deformation zone of
the part remaining from extrusion exhibited varied
microstructure characteristics. Rattanochaikul et al.
[13] reports a preliminary research and development
work of a new rheo-extrusion process using the Gas
Induced Semi-Solid (GISS) technique. The effects of
the plunger speeds and solid fractions on the
extrudability of an aluminum 356 alloy were
investigated. Pathak et al. [14] investigated a finite
element simulation of tube extrusion process by
different mesh adaptivity schemes. A comparison of
these schemes has been made based on stress, strain
distribution, and load-stroke curves. Khosravifard et
al. [15] a finite element analyses of rod extrusion
process are carried out considering various
processing parameters. They investigated the effect
of these parameters on mechanical performance.
Pathak et al. [16] used genetic algorithm (GA) and
dynamic material modeling (DMM) for experimental
verification of a proposed extrusion die profile design
approach, which aims to satisfy micro structural
criteria at maximum production speed and minimum
left out material in the die cavity. Bovas et al. [17]
they investigated the effect of melt temperature on
the surface roughness and wettability of the catheter
surfaces were analyzed through ANOVA. Matli et al.
[18] a nano-sized Si3N4 (0, 0.5, 1.0 and 1.5 vol%)/Al
composites were fabricated using a powder
metallurgy method involving microwave sintering
technique followed by hot extrusion. The influence of
Si3N4 content on the structural, mechanical and
thermal behaviour of Al–Si3N4 nanocomposites was
systematically investigated. Chen et al. [19] the
isothermal hot compression tests of homogenized
7005 aluminium alloy at the deformation
temperatures ranging from 623 K to 823 K and with
the strain rates ranging from 0.001 s 1 to 10 s 1 were
conducted for constitutive analysis. Dong et al. [20] a
deep understanding of hot deformation behaviour of a
material plays a crucial role in determining process
parameters and designing extrusion dies during the
extrusion process of the aluminium alloy profiles.
Ebrahimi et al. [21] equal channel forward extrusion
process as a severe plastic deformation method has
been experimentally and numerically investigated on
the 6082 aluminium alloy. Gagliardi et al.[22]
investigated the porthole die profile used to produce
hollow complex cross-section profiles. 12 geometric
variables of a standard porthole die, used to extrude
profiles with circular section, were identified and
3. Yadav et al.
126
varied on three levels. 23. Parvizian et al. [23] they
modeled and simulate hot metal forming processes in
which material undergoes large deformations with
help of the Finite Element (FE) software ABAQUS
using Lagrangian formulation. Hosseini et al. [24] a
modified novel backward extrusion process
implementing severe plastic deformation is presented
for processing of ultrafine-grained materials. The
process was applied to commercially pure
aluminium, and microstructure and micro hardness
measurements were investigated. Ramezani and
Neitzert [25] developed FE model can be used for
investigating direct extrusion and selecting
appropriate die design parameters for the process.
Reddy et al. [26] investigated pure aluminium for
Equal Channel Angular Extrusion (ECAE)
processing. Kapadia and Desai [27] investigated both
analytical and simulation result. Simulation of direct
extrusion of Aluminum alloy (6063) in the form of
round circular billet to round circular solid profile is
done. Ghaemi et al. (2013) [28] investigated on the
shape of die profile. Extrusion process through both
optimum conical and curved die has been performed
experimentally and also by finite element method.
2.Overview of extrusion process
2.1Material utilised in extrusion process
Metals that are commonly extruded include
Aluminium, Brass, Copper, Lead and tin,
Magnesium, Zinc, steel, Titanium. Aluminium is
most commonly extruded material. Aluminium can
be hot or cold extruded, If it is hot extruded it is
heated to (300 to 6000C). Magnesium and
Aluminium alloys have a 0.75 micrometer RMS or
better surface finish. Titanium and steel can achieve a
3 micrometers RMS. Table 1 shows the description
of the author who have used variety of material as a
extruded material for manufacturing by extrusion
process. It is clear from table that in majority of the
researchers have used Al materials. Some cases they
have also used different Magnesium alloy for
extrusion process.
Table 1 Metal used work piece by previous researchers
Author Year Material
Subramanian and, Palaniradja [1] 2018 Magnesium alloy
Akhgar et al. [6] 2011 AA6061-5% Sicp
Pourbahari et al. [7] 2018 MG-Gd-Al-Zn magnesium alloy
Tahmasbi et al. [8] 2018 Aluminium alloy AA7022
Chen et al. [12] 2018 Az 91 alloy
Rattanochaikul et al. [13] 2017 Aluminium 356 alloy
Matli et al. [18] 2017 Al-Si3N4 nano compoites
Chen et al. [19] 2015 7005 Aluminium alloy
Dong et al. [20] 2016 AA6N01
Ebrahimi et al. [21] 2016 6082 Aluminium alloy
Ramezani and neitzert et al.[25] 2016 Ti-6Al-4v powder alloy
Kobayashi et al.[27] 1989 Al alloy (6063)
2.2FEM modelling of extrusion process
Finite element simulation is considered as a powerful
and efficient methodology for obtaining defect free
products in extrusion process, as various researchers
applied this method in the past. Jain et al. [14]
conducted FEM simulation of tube extrusion process
using aluminum as billet material and steel as die-
material. Figure 4 shows the schematic illustration of
tube extrusion process and Figure 5 shows FEM
model of axisymmetrical tube extrusion. Table 2
shows the material properties of the billet and die.
4. International Journal of LNCT, Vol 2(6)
127
Materials for die and tube are die steel and
aluminium, respectively
Figure 4 Tube extrusion setup [14]
Figure 5 FEM Simulation [14]
Table 2 Material properties of billet and die materials
Material
Properties
Billet Die
Young’s
Modulus (Mpa)
70000 220000
Yield Strength
(Mpa)
80 1200
Poisson ratio 0.3 0.3
Hardening
Component
0 0
Hirt et al. (2017) utilized commercial software
package ABAQUS for three-dimensional FEM
simulation of hybrid forward extrusion process. They
performed a thermo- mechanical and electrical
analysis of forward extrusion process. Figure 6 (a)
shows the solid forward extrusion process with
resistive heating, Figure 6 (b) shape of the formed
part and computer tomographic image of cold and
warm formed part in the region of extrusion shoulder
three. Figure 6 (c) shows geometry of extrusion die
.Figure 6 (d) shows the flow curves for different
temperatures at at a constant strain rate of 1 s-1
.
Figure 6 (a) Solid forward extrusion process with
resistive heating
Figure 6 (b) Shape of the formed part and computer
tomographic image of cold and warm formed
Figure 6 (c) Shows geometry of extrusion die
5. Yadav et al.
128
Figure 6 (d) Shows the flow curves for different
temperatures at constant strain rate of 1 s-1
Figure 6 a)solid forward extrusion process extended
with resistive heating b) shape of the formed part and
computer tomographic image of cold and warm
formed part in the region of extrusion shoulder three
c) geometry of the extrusion die d) flow curves for
different temperatures at a constant strain rate of 1 s-1
.
[2] Mahnken et al. (2010) (23) they modelled and
simulate hot metal forming processes in which
material undergoes large deformations with help of
the Finite Element (FE) software ABAQUS using
Lagrangian formulation. The microstructure
evolution is modelled effectively with the help of
internal state variables. Element distortion and
contact during the re meshing simulation of large
deformation processes is controlled with the help of a
custom adaptive remeshing system based on Python
scripting and utilisable in commercial programs such
as ABAQUS. Element distortion of material can be
by using an adaptive remeshing scheme. They
improved the quality of the mesh of number of
elements during the simulation. Figure 6 is done by
using the adaptive refinement. After each small time
step, the distorted elements will be identified in a
post processing step. Then the distorted elements
divided into smaller elements. The number of
elements started from around 2000 at beginning of
the simulation and increases up around8000 at the
end of the simulation.
Figure 6 Simulation of extrusion process using
adaptive mesh refinement
Figure 7 Mesh topology in simulation of forging
process using remeshing scheme
3.Result and discussion
The FE model presented different types of result
there are force predicted by the FE simulation, the
forces are shown together with the corresponding
measured force from experimental for three condition
cold, preheated and hybrid condition in Figure 3. As
a good match of the rising force at each projection at
nearly the same punch stroke in experiment and
simulation is an indication of the properly
implemented re meshing procedure and volume loss
is negligible.
6. International Journal of LNCT, Vol 2(6)
129
Figure 8 Comparison of measured and simulated
punch forces for (a) cold (b) pre-heated to 450°C and
(c) hybrid condition.[2]
The thermo mechanically coupled extrusion process
of aluminium alloys and forging of steels, both are
implemented as user material subroutines (UMAT) in
FE software ABAQUS. The CAX4TR element which
is quadrilateral axisymmetric element are applied
with temperature as a degree of freedom in a coupled
temperature-displacement simulation. ABAQUS
gives to the output database of the simulation results
by using the Python programming language. The
system enables us to check the mesh quality or any
other remeshing criteria in a post processing step.
4.Conclusion and future work
In the body of work presented in this paper, extrusion
process is studied by considering various aspects of
extrusion process. A brief and concise review of the
contributions made by the previous researchers in the
area of extrusion process is also presented. It is found
that researchers have utilized aluminium material for
extrusion as workpiece material in majority of cases,
however in the recent past, the usage of steel alloy
has also been started. It has also been found that
researchers carried out FEM modelling of extrusion
process by employing axisymmetric conditions and
modelled problem with half and quarter geometry.
Meshing of the die is done by using axisymmetric
quadrilateral elements. FEM simulation is found be
powerful and efficient methodology in analysis of
metal extrusion process.
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