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Extrusion software
- 1. COLDFORGINGEXTRUSION SOFTWARE Supervised By Prof. Dr.Abdallah Wifi T.A. Mohamed Al-Mo’ayed Prepared By Group One Anton Tamer Shafique Ayman Hisham Mahmoud Sarah Hossam Marzouk Mohamed Ahmed Morsy Mohamed Ashraf Mohamed Mahmoud Ahmed El-Sayed Hager Ali Mahmoud Ali B.N: 12 B.N: 13 B.N: 15 B.N: 23 B.N: 24 B.N: 28 B.N: 35 CAMF2
- 2. Contents ◉ Introduction ◉ Problemstatement ◉ Overview ◉ Graphical User Interface ◉ Program Base Calculations ◉ Program Work Principal ◉ Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison ◉ Program Additional Feature ◉ Conclusion 2
- 3. Introduction ◉ Cold extrusion ○Used in: Cans , collapsible tubes & fire extinguishers ○ The first extrusion process for pipe making was patented by Joseph Bramah in 1797.. 3
- 4. Introduction ◉ Importance ofComputer Aided Metal Forming ■ Increasing level of automation. ■ Maintaining competitiveness. ■ Available for smaller factories, at a reasonable price. 4
- 5. Problem Statement A programthat calculates the tonnage & force of a press rapidly depending on product type & dimensions. 5 Based on the idealized calculations
- 6. Overview 6 1. Row Material Dimensions 2.Force ( forward & backward) 3. Machine Press Capacity 4. Machine Configuration CALCULATE! Inputs Outputs 1. Five Materials or User Define Material 2. Three Product types 3. Dimensions
- 7. Graphical User Interface Inputs 7 ProductDimension Sketch
- 8. Graphical User Interface Errormassages 8 Calculated outputs Suggested Die Assembly Sketch
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- 11. Program Base Calculations 11 ForwardExtrusion • 𝑣 = 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑜𝑛 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑠ℎ𝑎𝑝𝑒 • 𝜑𝑝 = 𝑙𝑛 𝐴𝑜 𝐴1 • 𝐾𝑠𝑡𝑟𝑚 = 𝐾𝜑𝑝 𝑛 𝑛+1 • 𝐹 = 𝐴𝑝𝐾𝑠𝑡𝑟𝑚𝜑𝑝 𝜂𝐹 Backward Extrusion (Thick) • 𝐷𝑜 𝑆 ≤ 10, 𝑆 = 𝐷𝑜−𝐷𝑝 2 • 𝑣 = 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑜𝑛 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑠ℎ𝑎𝑝𝑒 • 𝜑𝑝 = 𝑙𝑛 𝐴𝑜 𝐴1 • 𝐾𝑠𝑡𝑟𝑚 = 𝐾𝜑𝑝 𝑛 𝑛+1 • 𝐹 = 𝐴𝑝𝐾𝑠𝑡𝑟𝑚𝜑𝑝 𝜂𝐹 𝜂𝐹 = 0.6 𝑤ℎ𝑒𝑛 𝜑𝑝 < 0.8 𝜂𝐹 = 0.7 𝑤ℎ𝑒𝑛 𝜑𝑝 > 0.8 𝜂𝐹 = 0.6 𝑤ℎ𝑒𝑛 𝜑𝑝 < 0.1 𝜂𝐹 = 0.7 𝑤ℎ𝑒𝑛 𝜑𝑝 > 0.1 𝑉𝐵𝑒𝑓𝑜𝑟𝑒 = 𝑉𝐴𝑓𝑡𝑒𝑟
- 12. Program Base Calculations 12 BackwardExtrusion (Thin) • 𝐷𝑜 𝑆 > 10, S = 𝐷𝑜−𝐷𝑝 2 • 𝑣 = 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑜𝑛 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑠ℎ𝑎𝑝𝑒 • 𝜑𝑝 = 𝑙𝑛 𝐷𝑜 𝐷𝑜−𝑑 ∗ 0.16 • 𝐹 = 𝐴𝑝𝐾𝑠𝑡𝑟𝑚 𝜂𝐹 (2 + 0.25 ℎ𝑜 𝑠 ) 𝜂𝐹 = 0.6 𝑤ℎ𝑒𝑛 𝜑𝑝 < 0.1 𝜂𝐹 = 0.7 𝑤ℎ𝑒𝑛 𝜑𝑝 > 0.1
- 13. Program Work Principal 13 StrainExponent Strain Coefficient Maximum Allowable Strains CAN-CAN ROD-ROD CAN-ROD Select or Define Material Select Product Type Set Suitable Dimensions Thin or Thick Backward Extrusion Calculate Strain Select Efficiency Calculate Row Material Dimensions
- 14. Program Work Principal 14 PartDrawing Schematic Die Set Proceed to Calculations Depends on Extrusion Type Calculate Mean Flow Stress Calculate the Forces Select the Maximum Calculate Machine Capacity Output Graphs
- 15. Hand Calculations(Idealized &Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison 15 For CAN-CAN Product 𝑑𝑜 60 𝑚𝑚 𝑑𝑝1 45 𝑚𝑚 𝑑𝑝2 45 𝑚𝑚 𝑦𝑏 35 𝑚𝑚 𝑡 10 𝑚𝑚 𝑦𝑓 35 𝑚𝑚 Hand Calculations (Idealized) 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 60 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 40.62 𝑚𝑚 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 1097334.4 𝑁 𝐹(𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑) = 257915.6 𝑁 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 111.85 𝑇𝑜𝑛𝑠
- 16. 16 CAMF 2 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟= 60 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 40.62 𝑚𝑚 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 1097300 𝑁 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 257934 𝑁 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 111.85 𝑇𝑜𝑛𝑠 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 17. 17 For CAN-CAN Product 𝑑𝑜 60𝑚𝑚 𝑑𝑝1 45 𝑚𝑚 𝑑𝑝2 45 𝑚𝑚 𝑦𝑏 35 𝑚𝑚 𝑡 10 𝑚𝑚 𝑦𝑓 35 𝑚𝑚 Hand Calculations (Semi-Empirical) 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 60 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 40.62 𝑚𝑚 P 𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑 = 2040.5 𝑀𝑃𝑎 P 𝐹𝑜𝑟𝑤𝑎𝑟𝑑 = 936.334 𝑀𝑃𝑎 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 330.6 𝑇𝑜𝑛𝑠 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 18. 18 EXTRUCAD 4 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦= 330.6 𝑇𝑜𝑛𝑠 P 𝑚𝑎𝑥 = 2040.5 𝑀𝑃𝑎 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 19. 19 For ROD-ROD Product 𝑑𝑜 40𝑚𝑚 𝑑𝑝1 28 𝑚𝑚 𝑑𝑝2 28 𝑚𝑚 𝑦𝑏 30 𝑚𝑚 𝑡 40 𝑚𝑚 𝑦𝑓 30 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 40 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 69.4 𝑚𝑚 𝐹 𝐹𝑜𝑟𝑤𝑎𝑟𝑑 = 431156.1 𝑁 𝐹(𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑) = 12976.6 𝑁 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 43.95 𝑇𝑜𝑛𝑠 Hand Calculations (Idealized) Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 20. 20 CAMF 2 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟= 40 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 69.4 𝑚𝑚 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 431193 𝑁 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 12978.7 𝑁 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 43.95 𝑇𝑜𝑛𝑠 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 21. 21 For ROD-ROD Product 𝑑𝑜 40𝑚𝑚 𝑑𝑝1 28 𝑚𝑚 𝑑𝑝2 28 𝑚𝑚 𝑦𝑏 30 𝑚𝑚 𝑡 40 𝑚𝑚 𝑦𝑓 30 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 40 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 69.4 𝑚𝑚 P 𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑 = 1991.3 𝑀𝑃𝑎 P(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 1211 𝑀𝑃𝑎 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 130 𝑇𝑜𝑛𝑠 Hand Calculations (Semi-Empirical) Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 22. 22 EXTRUCAD 4 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦= 130 𝑇𝑜𝑛𝑠 P 𝑚𝑎𝑥 = 1991.3 𝑀𝑃𝑎 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 23. 23 For CAN-ROD Product 𝑑𝑜 60𝑚𝑚 𝑑𝑝1 45 𝑚𝑚 𝑑𝑝2 45 𝑚𝑚 𝑦𝑏 35 𝑚𝑚 𝑡 10 𝑚𝑚 𝑦𝑓 35 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 60 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 45 𝑚𝑚 𝐹 𝐹𝑜𝑟𝑤𝑎𝑟𝑑 = 823905.1 𝑁 𝐹(𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑) = 257915.6 𝑁 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 83.98 𝑇𝑜𝑛𝑠 Hand Calculations (Idealized) Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 24. 24 CAMF 2 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟= 60 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 45 𝑚𝑚 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 823913 𝑁 𝐹(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 257934 𝑁 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 83.98 𝑇𝑜𝑛𝑠 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 25. 25 For CAN-ROD Product 𝑑𝑜 60𝑚𝑚 𝑑𝑝1 45 𝑚𝑚 𝑑𝑝2 45 𝑚𝑚 𝑦𝑏 35 𝑚𝑚 𝑡 10 𝑚𝑚 𝑦𝑓 35 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 60 𝑚𝑚 𝑆𝑡𝑜𝑐𝑘 𝐻𝑖𝑔ℎ𝑡 = 45 𝑚𝑚 P 𝐵𝑎𝑐𝑘𝑤𝑎𝑟𝑑 = 2040.5 𝑀𝑃𝑎 P(𝐹𝑜𝑟𝑤𝑎𝑟𝑑) = 954.91 𝑀𝑃𝑎 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 330.6 𝑇𝑜𝑛𝑠 Hand Calculations (Semi-Empirical) Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 26. 26 EXTRUCAD 4 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦= 330.6 𝑇𝑜𝑛𝑠 P 𝑚𝑎𝑥 = 2040.5 𝑀𝑃𝑎 Hand Calculations(Idealized & Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison
- 27. 27 Comparison Results Hand Calculations(Idealized& Semi-Empirical), EXTRUCAD 4 and CAMF 2 Comparison Result Hand calculation (Idealized) MATLAB Software Hand Calculation (Semi-Empirical) EXTRUCAD4 Can-Can 111.85 Tons 111.85 Tons 330.6 Tons 330.6 Tons Rod-Rod 43.95 Tons 43.95Tons 130 Tons 130 Tons Can-Rod 83.98 Tons 83.98 Tons 330.6 Tons 330.6 Tons
- 28. Program Additional Feature 28 DefiningMaterial (Equivalent to CK10) With the Same Dimensions
- 29. Coclusion 29 ◉ Cold ForgingSoftware Can Make Multiple Iterations for Multiple Products in No Time. ◉ The Software is not limited with Chosen Materials. ◉ For CAMF2, there is NO DIFFRERNCE with Idealized Hand Calculations. ◉ For EXTRUCAD4, there is a BIG DIFFERENCE with Idealized Hand Calculation, Because it uses Semi-Empirical Equations.
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Editor's Notes
- #4 He made pipe out of soft metals forced through a die with the use of a hand-driven plunger
- #5 Another characteristic of this industry is a rapid development and widespread application of CAD/CAM systems. This can be explained by several reasons: - The increasing level of automation of main production processes requires the automation of auxiliary processes as well. This is especially valid for the design phase. - To maintain competitiveness, it is necessary to increase the flexibility both in design and manufacturing: the only way to meet these requirements is the implementation of complexCAD/CAM systems to reduce time and labour required for design and manufacturing. - Recent developments in computer hardware and pheripherials make these systems available even for smaller factories, at a reasonable price.
- #6 Another characteristic of this industry is a rapid development and widespread application of CAD/CAM systems. This can be explained by several reasons: - The increasing level of automation of main production processes requires the automation of auxiliary processes as well. This is especially valid for the design phase. - To maintain competitiveness, it is necessary to increase the flexibility both in design and manufacturing: the only way to meet these requirements is the implementation of complexCAD/CAM systems to reduce time and labour required for design and manufacturing. - Recent developments in computer hardware and pheripherials make these systems available even for smaller factories, at a reasonable price.